Page 2 In the event of accident repairs, crash safety must be an absolute priority. To maintain optimum crash safety, all structural work must be done correctly as indicated. The repair work may only be carried out by Ferrari-trained and certiﬁed skilled personnel. Only genuine parts should be used when carrying out the repair.
Page 3 The sections are joined to the extruded members of the sill (B) by die-cast node joints. The sill (B) of the Ferrari F458 Italia is oversized, as on a cabriolet type vehicle. This means that the Ferrari F458 Italia makes no compromises where crash safety is concerned.
Page 4 1.3 General safety instructions Explanation of safety instructions Danger! “Danger” indicates imminent hazards that may result in death or serious injury. Warning! “Warning” indicates potential hazards that may result in death or serious injury. Caution! “Caution” indicates potential hazards that may result in slight injury.
Page 5 1.3 General safety instructions When carrying out any of the procedures described in this 1.3.2 Handling body and assembly components with sharp repair manual, please observe all national accident safety edges regulations. Caution! 1.3.1 Lifting vehicles Risk of injury from sharp-edged burrs on body and accessories.
Page 6 1.3 General safety instructions 1.3.3 Working in presence of aluminium dust 1.3.4 Handling batteries Warning! Warning! Risk of explosion from high concentrations of aluminium Risk of explosion and ﬁre from ﬂying sparks during dust. Risk of injury from breathing in ﬁne particulate. grinding and welding work.
Page 7 1.3 General safety instructions 1.3.5 Grinding and welding • When welding, wear suitable, non-ﬂammable protective clothing and gloves. Warning! • When carrying out grinding and welding work around the Risk of explosion and ﬁre when welding in the vicinity fuel tank or fuel-carrying parts, ensure that these parts do of highly ﬂammable substances.
Page 8 1.3 General safety instructions 1.3.6 Removing sealants 1.3.7 Handling chemicals Danger! Caution! Risk of death from inhaling toxic vapours. Risk of burns Handling chemicals may cause allergic skin and in the event of direct skin contact with hydrochloric respiratory tract reactions. acid.
Page 9 1.3 General safety instructions 1.3.8 Working with the air conditioning system 1.3.9 Handling the airbag system Warning! Caution! Risk of injury from the charged air conditioning system Risk of injury from activation of airbag units if earth exploding during welding work. strap is not disconnected.
Page 10: Important Information
1.4.1 Assessing the extent of the damage In the case of accidents involving substantial areas of the • Repair work on the Ferrari F458 Italia must only be carried vehicle, examine the following components carefully to out by repair personnel who have been trained, tested and prevent any damage to vehicle or suspension parts from going certified by the Ferrari Customer Service department.
Page 11 • To ensure crash safety, these joints must be rewelded in the original positions after a body repair. • Any methods and procedures that deviate from the original assembly are described in the Ferrari F458 Italia bodywork repair manual. 1.4.4 Cuts • Cuts must only be made as described by the instructions...
Page 12 1.5 Key to symbols 1.5.1 Welding SG tack weld SG plug weld SG continuous weld SG staggered continuous weld Spot weld (SG = shield gas welding) 1.5.2 Riveting Solid and self-piercing rivet with countersunk head Blind rivet with countersunk head Copyright ©...
Page 13 1.5 Key to symbols 1.5.3 Milling off, drilling out or piercing spot welds Mill off spot weld Drill out or pierce 1.5.4 Gluing and sealing Bicomponent sealant mastic Area to be sealed with mastic 1.5.5 Cavity preservation 1.5.5 Screw symbol 1.5.5 Cutting and grinding points for weld seams Copyright ©...
Page 14 1.6 Clearances 1: Roof/Windscreen 3: Side window/Roof Clearance = 4.0 mm ±1.0 mm Clearance = / Offset = -2.0 mm -1.0 mm +1.5 mm Offset = -8.5 mm ±1.5 mm 2: Roof/Windscreen 4: Roof/Fender Clearance = 4.0 mm ±2.0 mm Clearance = Minimum point 3.0 mm (variable) ±1.5 mm Offset = variable Offset = /...
Page 15 1.6 Clearances 5: Lid/Bumper 7: Headlight/Fender Clearance = 3.5 mm ±0.5 mm Clearance = 3.0 mm ±1.0 mm Offset = -1.0 mm ±1.0 mm Offset = +0.7 mm ±0.7 mm 6: Fender/Bumper grille 8: Headlight/Bumper Clearance = 0.0 mm +0.5 mm Clearance = 3.0 mm ±1.0 mm Offset = 0.0 mm ±0.5 mm Offset = variable...
Page 16 1.6 Clearances 9: Bumper/Headlight/Grille 11: Fender/Lid Clearance = 3.0 mm ±1.0 mm Clearance = 3.5 mm ±0.5 mm Offset = / Offset = 0.7 mm +0.7 mm -1.0 mm 10: Headlight/Lid 12: Roof seal/Front window surround Clearance = 3.5 mm ±0.5 mm Clearance = 5.5 mm ±1.5 mm Offset = -1.4 mm ±1.0 mm Offset = /...
Page 17 1.6 Clearances 13: Fender/Sill trim panel 15: Side door/Sill trim panel Clearance = 4.0 mm ±0.7 mm Clearance = 4.0 mm ±1.5 mm Offset = -0.5 mm ±0.5 mm Offset = 0.0 mm ±1.0 mm 14: Door panel/Fender 16: Moulding/Door window Clearance = 3.5 mm ±0.5 mm Clearance = / Offset = -0.5 mm +0.5 mm...
Page 18 1.6 Clearances 17: Roof/Moulding 19: Quarterlight/Door window Clearance = / Clearance = 6.3 mm ±2.0 mm Offset = -1.0 mm ±1.0 mm Offset = Var. -0.8/-0.7 mm ±1.0 mm 18: Door panel/Flank 20: Quarterlight seal/Door window scraper seal Clearance = 3.5 mm ±0.5 mm Clearance = 2.5 mm ±0.5 mm Offset = 0.75 mm +0.0 mm -0.75 mm Offset = 0.0 mm ±1.0 mm...
Page 19 1.6 Clearances 21: Air intake surround/Roof 23: Roof/Rear window Clearance = 3.5 mm ±0.5 mm Clearance = 4.5 mm +1.0 mm Offset = -1.0 mm ±1.0 mm Offset = -1.0 mm +0.0 mm 22: Rear window/Air intake surround 24: Rear window/Engine compartment lid Clearance = 3.0 mm ±1.0 mm Clearance = 4.0 mm ±1.0 mm Offset = -0.0 mm ±1.0 mm...
Page 20 1.6 Clearances 25: Engine compartment lid/Rear bumper 27: Taillight/Rear bumper Clearance = 4.0 mm ±1.0 mm Clearance = Var. from 2.7 mm to 3.8 mm +1.0 mm Offset = 0.0 mm ±1.0 mm Offset = / 26: Taillight/Exterior ﬂank 28: Air intake grilles/Rear bumper Clearance = 3.0 mm ±1.0 mm Clearance = 0.0 mm +0.5 mm Offset = /...
Page 21 1.6 Clearances 29: Lower air intake/Rear bumper 31: Lower air intake/Diffuser Clearance = 1.0 mm +0.5 mm Clearance = 2.0 mm +1.0 mm Offset = / Offset = / 30: Lower air intake/Diffuser 32: Air intake surround/Exterior ﬂank Clearance = 2.0 mm ±0.7 mm Clearance = 4.0 mm ±1.5 mm Offset = 0.0 mm ±0.5 mm Offset = /...
Page 22 1.6 Clearances 33: Rear window/Exterior ﬂank 35: Exterior ﬂank/Rear bumper Clearance = 4.0 mm ±1.5 mm Clearance = 0.0 mm ±0.5 mm Offset = / Offset = 0.0 mm ±0.5 mm 34: Engine compartment lid/Rear bumper Clearance = 4.0 mm ±1.5 mm Offset = Var.
Page 23 A special set of straightening tools has been developed for repairing the Ferrari F458 Italia. To ensure precise ﬁt and dimensional accuracy, it is generally advised to use the set of straightening tools when carrying out all work on the vehicle structure: •...
Page 32 Single component permanently elastic adhesive mastic This material is applied in very narrow repair areas, and in the outer skin area in particular. For example, on the Ferrari F458 Italia, this is used to hermetically seal the underdoor panel. Copyright ©...
Page 33 1.9 Workstation for bodywork repairs A specially equipped workstation is necessary for carrying out repairs on the aluminium bodywork of the Ferrari F458 Italia. If the workstation is not situated in its own dedicated, enclosed space, adjacent workstations used for conventional steel vehicles must be screened off with a sliding protective curtain.
Page 34 The following tools are generally required for carrying out work on vehicle bodies: • Gun for applying cavity wax • Counterhold tool • Set of straightening tools - Ferrari F458 Italia • Universal dolly • Portal gauge • Plastic wedges •...
Page 35 1.10 Workshop equipment for aluminium repairs Special tools A new template and punch kit (p/n 95978256) is used for repairs in the wheelhouse area. These tongs enable the removal and replacement of rivet joints at the ﬂange connecting the two halves of the wheel housing.
Page 36 1.11 Aluminium Aluminium is obtained from bauxite and is the second most commonly used metal today after steel. Magnesium and silicon are the main alloying components used in high-quality aluminium alloys. These alloys form the basis of the extruded sections, die-cast node joints and panels in aluminium. 1.11.1 Contact corrosion When aluminium is in contact with oxygen in the air, a passivating oxide layer is formed on its surface that protects the material...
Page 37 1.11 Aluminium 1.11.2 Corrosion protection 1.11.3 Screw connections To prevent contact corrosion, only surface-coated fastener Caution! elements - bolts, nuts, washers, blind rivets, self-piercing rivets, etc. - are used in the manufacture of the vehicle. These Bolts must not be reused. Friction produced during components are tested for their compatibility with aluminium.
Page 38 1.11 Aluminium 1.11.5 Space-Frame assembly The entire bodywork of the Ferrari F458 Italia is constructed on a Space Frame structure. The areas highlighted in purple are made from an aeronautical grade aluminium alloy. Extruded sections and cast parts are all welded in the area of the join.
Page 39 1.11 Aluminium 1.11.6 Extruded sections 1.11.8 Gussets (reinforcement panels) The vehicle is ﬁtted with gussets (reinforcement panels) in Caution! different thicknesses. The gussets are mainly attached to the space frame by means of welded or riveted joints. Deformed extruded sections must not be repaired either cold or by applying heat.
Page 40 The joints between aluminium body components and steel components must meet extremely high requisites in terms of strength and corrosion resistance. On the Ferrari F458 Italia, these requirements have been met by joining the components using non-thermal procedures and coated self-piercing rivets.
Page 41 1.13 Consumable materials Only the consumable materials listed must be used when carrying out any of the body repairs described in this manual. All materials must be approved by the vehicle manufacturer. Name Manufacturer Product number Speciﬁcation Bicomponent cartridge gun for 3M Scotch-Weld EPX 37/50 structural adhesive (end-cured)
Page 42 1.13 Consumable materials Name Manufacturer Product number Speciﬁcation Butyl tape Henkel/Teroson Permanently-elastic sealant, 8 mm Single component primer Henkel/Teroson Cleaner (for painted areas) Henkel/Teroson Silicone remover Henkel/Teroson Copyright © 2010...
Page 43 1.14 Preparing and cleaning areas for welding Often, for the sake of convenience or due to a shortage of time, joint areas are not adequately prepared and cleaned correctly, in spite of the fact that these preliminary procedures are vital for a perfect, high quality weld.
Page 44 1.15 Repair methods 1.15.1 Panel beating 1.15.3 Monitoring temperature NOTE! Caution! Only use aluminium tools for all panel beating work. Outer skin body components may be heated for straightening and panel beating work provided the The risk of stretching the material is greater with aluminium than with steel.
Page 45 1.15 Repair methods 1.15.4 Cutting 1.15.5 Joggling Joggling is a particularly suitable method for creating a backing Caution! for welding aluminium panels. This should be carried out using mechanical or pneumatic joggling tools. Before making a Only perform cuts in accordance with the instructions cut, allow 22 mm for an overlap.
Page 46 Self-piercing riveting is one of the most important joining sprung tip. techniques used on the bodywork of the Ferrari F458 Italia. This technique is used to join aluminium body components Sparks produced when grinding are an indication together and to join aluminium with steel body components.
Page 47 The threaded rivets must also be repair. Use only blind rivets that have been approved completely removed from cavities. by Ferrari. These blind rivets are coated and prevent contact corrosion. The operating pressure for the pneumatic riveting tongs must be 8 bar. Before starting...
Page 48 1.15 Repair methods 1.15.9 Welding aluminium 1.15.10 Checking weld seams and die-cast node joints Metal inert gas (MIG) welding is the most commonly used Caution! method for carrying out repair welds on aluminium. It is used to create joints between castings and extruded sections and Before using any penetrating agents, cleaners and between panel sections.
Page 49 1.15 Repair methods Do not brush the area to be examined before carrying out a crack test as this will ﬁll up the cracks! Procedure: 1. Expose the damaged area and clean the surface. 2. Apply the penetrating agent with an aerosol spray can. The penetrating agent will permeate into the apertures in the surface by capillary action.
Page 50 1.15 Repair methods 1.15.11 Welding defects Cracks The most common types of cracks in aluminium are cracks caused by heat and/or solidiﬁcation; the risk of crack formation increases with increasing solidiﬁcation. Cracking in welds is primarily inﬂuenced by the composition of alloys being welded.
Page 51 1.15 Repair methods To repair a crack, the weld bead must be ground along the full length of the crack to twice the depth of the crack itself before repeating the weld (Fig. C). After welding, crack testing must be repeated. Cracks in the outer skin are repaired by drilling a 2 mm diameter hole at each end of the crack to prevent it from spreading.
Page 52 1.15 Repair methods Pores Pores within the weld bead constitute the most frequently encountered defect. Pore formation reduces with increasing solidiﬁcation intervals. Pores are formed by the inclusion of gas bubbles in the event of excessively rapid cooling. This is caused by the greater solubility of hydrogen in liquid aluminium (20 times higher than in the solid state).
Page 53 1.15 Repair methods Inclusions The most frequent types of inclusions are oxides. These form when small fragments of oxide ﬁlm fall into the weld pool, as the oxide layer was not removed prior to welding. As these fragments are in general very ﬁne and uniformly distributed, they have no discernible inﬂuence on the strength of the weld bead.
Page 54 1.15 Repair methods Melting The weld may melt in the event of excessive weld currents or inadequate edge preparation (Fig. I). Application error ('I' shaped bead) Application errors occur when the ﬁlling material runs into the gap and when a weld is applied on top of another newly applied bead that has not yet solidiﬁed.
Page 55 1.15 Repair methods Cold spots Cold spots may occur at the start and end of the bead, which compromise the strength of the joint due to poor penetration. As a result, approximately 5 mm should be added to the start and ﬁnish of the bead when determining the length of the bead itself.
Page 56 1.15 Repair methods 1.15.12 Structural adhesive bonding Sealing seams that have not been done correctly or that are missing may also cause wind noise. Bonded joints are also used in certain areas to supplement the self-piercing or blind rivet joints and resistance spot welds. Even the tiniest gap in the seal can result in substantial water This increases the strength of the joint.
Page 58 2.1 Replacing the fender Repair sequence Removing the old part 1. Use a 10 mm wrench to remove the 2 fastener screws joining the fender and the ﬂank of the vehicle. 2. Use a 10 mm wrench to remove the 4 fastener screws joining the fender and fender mounting.
Page 59 2.1 Replacing the fender 3. Use a 10 mm wrench to remove the fastener screw joining the fender and the front sill pillar. Fitting the new part 4. Fit the fender, aligning with the holes on the fender mounting and on the vehicle ﬂank. Copyright ©...
Page 60 2.1 Replacing the fender Fitting the 5. Fasten the fender to the fender mounting with 4 M6 new part screws. Caution! Do not reuse the screws removed previously. See paragraph (1.11.3 Screw connections). 6. Fasten the fender to the front sill pillar with 1 M6 screw.
Page 61 2.1 Replacing the fender 7. Fasten the fender to the vehicle ﬂank with 2 M6 screws. Caution! Do not reuse the screws removed previously. See paragraph (1.11.3 Screw connections). Reﬁt connected parts (bumper, headlight, gravel guard). Check the clearance dimensions, rework if necessary.
Page 62 2.2 Replacing the fender mounting assembly Preliminary Remove connected parts (bumper, headlight, hinges, lid) procedures Remove the fender (see chapter 2.1) Place the vehicle on the vehicle bench. Replacement parts • Front fender mounting (A) • Reinforcement base (B) Material necessary •...
Page 63 2.2 Replacing the fender mounting assembly Repair features Warning! Work with the utmost caution when welding to avoid igniting any components in the vicinity. Repair sequence Removing the old part 1. Sand the weld points between the fender mounting and the front trellis. Copyright ©...
Page 64 2.2 Replacing the fender mounting assembly 2. Remove the beads of bicomponent sealant mastic near the three fastener rivets joining the mounting base and the upper diagonal brace. Danger! Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive! Wear breathing protection, protective gloves and safety glasses.
Page 65 2.2 Replacing the fender mounting assembly 4. Remove the 4 self-piercing rivets joining the fender mounting and the lower reinforcement base. • 2 on outer side of vehicle. • 2 on inner side of vehicle. NOTE! Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
Page 66 2.2 Replacing the fender mounting assembly 6. Retrieve the protective foam. 7. Remove the lower mounting base and sand the welding points for joining the fender mounting and the upper diagonal brace. NOTE! Do not remove any other material from the upper diagonal brace.
Page 67 2.2 Replacing the fender mounting assembly Fitting the new part 8. Sand the new part. 9. Fit the outer tower, then mount the fender mounting in the jig (B - C). Prepare the weld area (see chapter 1.14). Copyright © 2010...
Page 68 2.2 Replacing the fender mounting assembly Fitting the new part NOTE! Before ﬁtting the new part, read chapter (1.15 Repair methods) thoroughly. 10. Weld the fender mounting to the front lateral trellis at the original weld points. 11. Weld the fender mounting to the upper diagonal brace at the original weld points.
Page 69 2.2 Replacing the fender mounting assembly 12. Fasten the reinforcement base to the upper diagonal brace with 3 structural rivets. 13. Fasten the reinforcement base to the fender mounting with 4 self-piercing rivets. • 2 on outer side of vehicle. •...
Page 70 2.2 Replacing the fender mounting assembly 14. Fasten the reinforcement base to the fender mounting with 4 structural rivets. • 2 on outer side of vehicle. • 2 on inner side of vehicle. 15. Reﬁt the protective foam. Copyright © 2010...
Page 71 2.2 Replacing the fender mounting assembly 16. Seal the three structural rivets joining the reinforcement base and the upper diagonal brace with bicomponent mastic. Danger! Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive! Wear breathing protection, protective gloves and safety glasses.
Page 72 2.3 Replacing the front lateral trellis Preliminary Remove connected parts (headlight, gravel guard, radiator, radiator mounting). procedures Remove the fender (see chapter 2.1). Place the vehicle on the vehicle bench. Replacement parts • Front lateral trellis (A) • Upper outer radiator mounting bracket (B) •...
Page 73 2.3 Replacing the front lateral trellis Removing the old part Repair sequence 1. Sand the weld points between the front trellis and the front spar. NOTE! Do not remove any other material from the front spars. 2. Sand the weld points joining the upper outer radiator mounting bracket.
Page 74 2.3 Replacing the front lateral trellis 3. Sand the weld points on the internal side of the car between the trellis and the cross-member. NOTE! Do not remove any other material from the front cross-member. 4. Sand the weld points between the trellis and the shock tower.
Page 75 2.3 Replacing the front lateral trellis 5. Sand the weld points between the trellis and the fender mounting. 6. Sand the weld points between the front link tube, the front lateral trellis and the front cross-member. Copyright © 2010...
Page 76 2.3 Replacing the front lateral trellis 7. Mount the front trellis in the jig. Fitting the new part NOTE! The procedure described above must be performed with the assistance of another worker. Prepare the weld area (see chapter 1.14). Fitting the new part NOTE! Before ﬁtting the new part, read chapter (1.15 Repair methods) thoroughly.
Page 77 2.3 Replacing the front lateral trellis 9. Mount the bracket (A) in the jig and weld at the original weld points to both the front trellis and the cross-member. 10. Weld the front trellis to the front spar at the original weld points.
Page 78 2.3 Replacing the front lateral trellis 11. Fit and then weld the link tube (B) to the front cross- member and to the front lateral trellis at the original weld points. 12. Weld the front trellis to the shock tower at the original weld points.
Page 79 2.3 Replacing the front lateral trellis 13. Weld the front trellis to the fender mounting at the original weld points. Apply new corrosion inhibitor to the entire repair area and then apply a primer coat. 14. Reﬁt the fender (see chapter 2.1). Reﬁt the door and lid.
Page 80 2.4 Replacing the front cross-member Preliminary Remove connected parts (bumper, headlights, radiator, tub). procedures Remove the fender (see chapter 2.1). Place the vehicle on the vehicle bench. Replacement parts • Front cross-member (A). • Upper outer radiator mounting bracket (B). Material necessary •...
Page 81 2.4 Replacing the front cross-member Repair sequence Removing the old part 1. Use a 13 mm wrench to remove the 12 screws located on the internal side of the car in correspondence with the bumper mounting brackets. 2. Use a 13 mm wrench to remove the 6 screws in correspondence with the tow hook mounting.
Page 82 2.4 Replacing the front cross-member 3. Sand the weld points between the front cross- member and the front spars. NOTE! Do not remove any other material from the front spars. 4. Remove the 12 structural rivets (6 per side) connecting the front cross-member and the front spars.
Page 83 2.4 Replacing the front cross-member 5. Grind and clean the welds on the front spars. Caution! Work with the utmost caution, taking care not to damage the front spars. Fitting the new part 6. Mount the front cross-member in the jig. NOTE! Check that the cross-member is perfectly horizontal.
Page 84 2.4 Replacing the front cross-member Fitting the new part NOTE! Before ﬁtting the new part, read chapter (1.15 Repair methods) thoroughly. 7. Fit 4 structural rivets (2 per side) to ﬁx the front cross-member in position. NOTE! Check that the cross-member is ﬂush with the front spars on both sides.
Page 85 2.4 Replacing the front cross-member 9. Weld the front cross-member to the spars (external/ internal lateral and upper/lower) at the original weld points. 10. Fit the front lateral trellis (see chapter 2.3). Copyright © 2010...
Page 86 2.4 Replacing the front cross-member 11. Weld the two upper outer radiator mounting brackets to the cross-member and to the front lateral trellis at the original weld points. Apply new corrosion inhibitor to the entire repair area and then apply a primer coat. 12.
Page 87 2.4 Replacing the front cross-member 13. Fasten the tow hook bracket to the front cross- member with 6 M8 screws. Caution! Do not reuse the screws removed previously. See paragraph (1.11.3 Screw connections). 14. Reﬁt the RH/LH front trellises (see chapter 2.3). 15.
Page 88 2.5 Replacing the front spar Preliminary Remove connected parts (bumper, headlights, lid, radiator, tub) procedures Remove the fender (see chapter 2.1) Remove the front trellis (see chapter 2.3) Remove the front cross-member (see chapter 2.4) Place the vehicle on the vehicle bench. Replacement parts •...
Page 89 2.5 Replacing the front spar Repair sequence Removing the old part 1. Use a 13 mm wrench to remove the screws, located on the internal side of the car, fastening the rear luggage tub bracket. 2. Cut the front spar. Copyright ©...
Page 90 2.5 Replacing the front spar 3. Remove the 5 structural fastener rivets joining the front spar and the reinforcement mounting. NOTE! Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use. 4.
Page 91 2.5 Replacing the front spar 5. Sand the weld points between the reinforcement mounting and the shock tower. Remove the reinforcement mounting. NOTE! Do not remove any other material from the front spars. Caution! Check that there are no cracks in the shock tower.
Page 92 2.5 Replacing the front spar Fitting the new part 7. Rest the front spar in the relative recess on the shock tower. NOTE! Check that the front spar is perfectly horizontal. Prepare the weld area (see chapter 1.14). 8. Check that the height of the top surface of the spar at both the inner and outer vehicle points is exactly 689.5 mm.
Page 93 2.5 Replacing the front spar 9. Mount the front cross-member (A) in the jig, ensuring that it is ﬁtted correctly onto the two spars (B). Fitting the new part NOTE! Before ﬁtting the new part, read chapter (1.15 Repair methods) thoroughly. 10.
Page 94 2.5 Replacing the front spar 11. Check that the front cross-member (A) is ﬁtted correctly, removing from the front spars (B). Caution! Perform all the welds described as follows with the part still in the jig. Remove the jig only once the weld areas are cool.
Page 95 2.5 Replacing the front spar 13. Weld the reinforcement mounting to the shock tower at the original weld points. 14. Fasten the reinforcement mounting to the spar with 5 structural rivets. Copyright © 2010...
Page 96 2.5 Replacing the front spar 15. Weld the front spar to the reinforcement mounting at the original weld points. Apply new corrosion inhibitor to the entire repair area and then apply a primer coat. 16. Fasten the rear luggage tub bracket with 2 M8 screws.
Page 97: Reﬁt The Front Cross-Member (See Chapter
2.5 Replacing the front spar 17. Using the front cross-member as a template for drilling, drill the speciﬁed holes in the spar and then fasten the spar to the cross-member with 6 structural rivets (Ø 6.4). 18. Reﬁt the front cross-member (see chapter 2.4). 19.
Page 98 2.6 Replacing the wheel bay cover plate Preliminary Remove connected parts (dashboard, interior) procedures Place the vehicle on the vehicle bench. Replacement parts • Wheel bay cover plate (A) Material necessary • 11 structural rivets (Ø 4.8) • Bicomponent sealant mastic Copyright ©...
Page 99 2.6 Replacing the wheel bay cover plate Repair sequence Removing the old part 1. Remove the internal and external beads of sealant mastic around the wheel bay cover plate. Danger! Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive! Wear breathing protection, protective gloves and safety glasses.
Page 100 2.6 Replacing the wheel bay cover plate 3. Remove the 7 structural rivets from the lower part of the wheel bay cover plate. NOTE! Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use. 4.
Page 101 2.6 Replacing the wheel bay cover plate Fitting the new part 5. Fit the wheel bay cover plate in correspondence with the rivet holes on the upper diagonal brace and on the torque box. Prepare the weld area (see chapter 1.14). Fitting the new part NOTE! Before ﬁtting the new part, read chapter (1.15...
Page 102 2.6 Replacing the wheel bay cover plate 7. Perform all the welds connecting the wheel bay cover plate to the connected parts. Apply new corrosion inhibitor to the entire repair area and then apply a primer coat. 8. Apply new beads of sealant mastic in all areas where it was removed previously.
Page 103 2.7 Replacing the shock tower Preliminary Remove connected parts (complete interior, dashboard, front lid and hinges, tub) procedures Remove the fender (see chapter 2.1) Remove the fender mounting (see chapter 2.2) Remove the front lateral trellis (see chapter 2.3) Remove the front cross-member (see chapter 2.4) Remove the front spar (see chapter 2.5) Remove the roof skin (see chapter 3.3) Remove the wheel bay cover plate (see chapter 2.6)
Page 104 2.7 Replacing the shock tower Repair sequence Removing the old part 1. Remove the 4 M8 perforating screws fastening the casting link cross-member. 2. Remove the 2/4 M8 screws fastening the lower front suspension cross-member. Copyright © 2010...
Page 105 2.7 Replacing the shock tower 3. Remove the internal and external beads of sealant mastic on the lateral portion of the front ﬁrewall. Danger! Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive! Wear breathing protection, protective gloves and safety glasses.
Page 106 2.7 Replacing the shock tower 5. Remove the beads of sealant mastic on the weld points in the underbody between the shock tower and the semi-ﬂoorpan. Danger! Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive! Wear breathing protection, protective gloves and safety glasses.
Page 107 2.7 Replacing the shock tower 7. Sand the beads of joining weld between the underwindscreen covering, the upper diagonal brace and the A-pillar ﬂange. NOTE! Do not remove any other material from the upper diagonal brace. 8. Use the AVDEL FPM-35 gun to remove the 2 self-piercing fastener rivets (Ø...
Page 108 2.7 Replacing the shock tower 9. Cut the shock tower in multiple points to allow access for the removal of the welds on the cross-members and reinforcements. Caution! When making separating cuts, take the utmost care not to damage the casting joints. Check the location of any internal cross- member reinforcement on the new part in order to cut correctly.
Page 109 2.7 Replacing the shock tower 11. Sand the internal lower weld points connecting the shock tower and the front cross-member. Caution! Check carefully to ensure that there is no evident buckling in the ﬂoorpan and in the reinforcements connected to the centre tunnel. 12.
Page 110 2.7 Replacing the shock tower 13. Remove the 3x2 structural rivets connecting the windscreen valence and the shock tower. NOTE! Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use. 14.
Page 111 2.7 Replacing the shock tower 15. Remove the structural rivets (1 upper rivet and 3 lateral rivets on inner side) fastening the upper diagonal brace to the shock tower. NOTE! Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
Page 112 2.7 Replacing the shock tower 17. Gradually grind the joint welds between the upper diagonal brace connected to the tunnel and the shock tower. NOTE! Do not remove any other material from the upper diagonal brace connected to the tunnel. 18.
Page 113 2.7 Replacing the shock tower 19. Gradually grind the joint welds between the torque box and the shock tower, taking care not to damage the parts themselves. NOTE! Do not remove any other material from the torque box. 20. Remove the 2 structural rivets on the lower surface of the lower front suspension cross-member.
Page 114 2.7 Replacing the shock tower 21. Gradually grind the joint welds between the lower front suspension cross-member and the shock tower. NOTE! Do not remove any other material from the lower front suspension cross-member. Fitting the new part 22. Mount the shock tower in the jig and tack. Prepare the weld area (see chapter 1.14).
Page 115 2.7 Replacing the shock tower Fitting the new part NOTE! Before ﬁtting the new part, read chapter (1.15 Repair methods) thoroughly. 23. Fasten the shock tower to the torque box with 5 structural rivets. 24. Fasten the shock tower to the upper diagonal brace with 4 structural rivets.
Page 116 2.7 Replacing the shock tower 25. Fasten the shock tower to the windscreen valence with 3 structural rivets. 26. Fasten the lower front suspension cross-member to the shock tower with 2 structural rivets. Copyright © 2010...
Page 117 2.7 Replacing the shock tower Caution! Perform all the welds described as follows with the part still in the jig. Remove the jig only once the weld areas are cool. 27. Weld the shock tower to the torque box and to the front cross-member at the original weld points in the underbody.
Page 118 2.7 Replacing the shock tower 29. Weld the shock tower to the front cross-member at the original weld points in the passenger compartment interior. 30. Weld the shock tower to windscreen valence at the original weld points. Apply new corrosion inhibitor to the entire repair area.
Page 119 2.7 Replacing the shock tower 31. Weld the upper diagonal brace connected to the tunnel to the shock tower at the original weld points. 32. Weld the lower front suspension cross-member to the shock tower at the original weld points. Copyright ©...
Page 120 2.7 Replacing the shock tower 33. Weld the shock tower to the front ﬁrewall at the original weld points (passenger compartment interior/exterior). 34. Fit the wheel bay cover plate (see chapter 2.6). Copyright © 2010...
Page 121 2.7 Replacing the shock tower 35. Fasten the lower front suspension cross-member with 2/4 M8 screws. Caution! Do not reuse the screws removed previously. See paragraph (1.11.3 Screw connections). 36. Fasten the casting link cross-member to the shock tower with 4 M8 screws. Caution! Do not reuse the screws removed previously.
Page 122 2.7 Replacing the shock tower Fitting the 37. Use the AVDEL FPM-35 gun to apply the 2 self- underwindscreen piercing fastener rivets (Ø 4.8) connecting the covering underwindscreen covering to the vehicle ﬂank. NOTE! Insert the new self-piercing rivets next to the old rivet holes.
Page 123 2.7 Replacing the shock tower 39. Reapply the beads of mastic removed previously from the underwindscreen covering. Danger! Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive! Wear breathing protection, protective gloves and safety glasses.
Page 124 2.7 Replacing the shock tower 41. Reﬁt the roof skin (see chapter 3.3) 42. Reﬁt the front spar (see chapter 2.5) 43. Reﬁt the front cross-member (see chapter 2.4) 44. Reﬁt the front lateral trellis (see chapter 2.3) 45. Reﬁt the fender mounting (see chapter 2.2) 46.
Page 125 2.8 Replacing the front end module Preliminary Remove connected parts (complete interior, dashboard) procedures Remove the fender (see chapter 2.1) Remove the fender mounting (see chapter 2.2) Remove the front lateral trellis (see chapter 2.3) Remove the roof skin (see chapter 3.3) Remove the windscreen support rib (see chapter 3.4) Remove the wheel bay cover plate (see chapter 2.6) Place the vehicle on the vehicle bench.
Page 126 2.8 Replacing the front end module Repair sequence Removing the old part 1. Remove the shock towers (see chapter 2.7). 2. Cut the 3 lower diagonal braces near the welds on the centre tunnel and on the lower front suspension cross-member.
Page 127 2.8 Replacing the front end module 3. Cut the 2 upper diagonal braces near the welds on the centre tunnel. 4. Grind the welds between the diagonal braces and the centre tunnel. Caution! Carefully check that the centre tunnel is free of cracks.
Page 128 2.8 Replacing the front end module 5. Remove the beads of mastic on the front ﬁrewall (lower area/lateral portions). Danger! Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive! Wear breathing protection, protective gloves and safety glasses.
Page 129 2.8 Replacing the front end module 7. Grind the welds between the ﬁrewall, ﬂoorpan and centre tunnel. Caution! Take the utmost care not to damage the casting joints on the centre tunnel. Caution! Carefully check that there is no evident buckling on the reinforcements connected to the centre tunnel.
Page 130 2.8 Replacing the front end module Fitting the new part NOTE! Before ﬁtting the new part, read chapter (1.15 Repair methods) thoroughly. 9. Tack the two shock towers to the upper diagonal brace and to the torque box (see chapter 2.7). Caution! Perform all the welds described as follows with the part still in the jig.
Page 131 2.8 Replacing the front end module 11. Tack and then weld the two upper diagonal braces to the centre tunnel and to the two shock towers at the original weld points. 12. Weld and rivet the two shock towers at the original weld points (see chapter 2.7).
Page 132 2.8 Replacing the front end module 13. Fit the front ﬁrewall in the relative recess, holding it against the windscreen valence cross-member (A). 14. Weld the front ﬁrewall to the two shock towers (passenger compartment interior/exterior) at the original weld points. Copyright ©...
Page 133 2.8 Replacing the front end module 15. Weld the front ﬁrewall to the front cross-member and to the centre tunnel at the original weld points. 16. Weld the front ﬁrewall to the windscreen valence cross-member (passenger compartment interior/ exterior) at to the original weld points. Copyright ©...
Page 134 2.8 Replacing the front end module 17. Fasten the casting link cross-member to the shock towers with 4 M8 screws. Caution! Do not reuse the screws removed previously. See paragraph (1.11.3 Screw connections). Apply new corrosion inhibitor to the entire repair area and then apply a primer coat.
Page 135 2.8 Replacing the front end module 20. Reapply beads of sealant mastic in the entire portion adjacent to the front ﬁrewall (interior/exterior of passenger compartment). Danger! Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive! Wear breathing protection, protective gloves and safety glasses.
Page 136 2.8 Replacing the front end module 22. Reﬁt the windscreen support rib (see chapter 3.4) 23. Reﬁt the roof skin (see chapter 3.3) 24. Reﬁt the front lateral trellis (see chapter 2.3) 25. Reﬁt the fender mounting (see chapter 2.2) 26.
Page 137 3.1 Replacing the roof skin Preliminary Remove the connected parts (dashboard, interior trim, windows, doors, lateral seals, front lid and relative hinges, rear lid and procedures relative hinges). Remove the fender (see chapter 2.1). Remove the fender mounting (see chapter 2.2). Place the vehicle on the vehicle bench.
Page 138 3.1 Replacing the roof skin Repair sequence Removing the old part 1. Remove the beads of mastic in the windscreen adhesive bonding area. Danger! Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive! Wear breathing protection, protective gloves and safety glasses.
Page 139 3.1 Replacing the roof skin 3. Sand the weld points on the A-pillars. Caution! Take the utmost care not to damage the casting joints on the front sill pillar. 4. Sand the weld points on the C-pillars. Caution! Take the utmost care not to damage the casting joints on the rear sill pillar.
Page 140 3.1 Replacing the roof skin 5. Remove all the rivets in the lower windscreen area. NOTE! Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use. 6. Remove all the rivets in the upper windscreen area. NOTE! Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause...
Page 141 3.1 Replacing the roof skin 7. Using the 50 mm C-frame, remove all the rivets from the lateral windscreen frame areas. NOTE! High strength self-piercing rivets are used for the high strength steel reinforcements of the A- pillars. NOTE! Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
Page 142 3.1 Replacing the roof skin 9. Use a 10 mm wrench to remove the 4x2 M6 screws from the rear connector ﬁn joining the upper skin and the vehicle ﬂank. 10. Remove all the rivets on the rear connector ﬁn joining the upper skin and the vehicle ﬂank.
Page 143 3.1 Replacing the roof skin 11. Remove the beads of mastic from the lower part of the rain gutter. Danger! Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive! Wear breathing protection, protective gloves and safety glasses.
Page 144 3.1 Replacing the roof skin 13. Remove the spots of mastic from the rear part of the upper skin. Danger! Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive! Wear breathing protection, protective gloves and safety glasses.
Page 145 3.1 Replacing the roof skin Fitting the new part NOTE! Before ﬁtting the new part, reapply all the spots of foam removed previously. • Roof skin/underwindscreen rib joint • Upper reinforcement cross-members 15. Fit the new part, using the recesses in the windscreen valence cross-member as reference.
Page 146 3.1 Replacing the roof skin 17. Reﬁt the connected parts (door, fender, lid). Check clearances and rectify if necessary. Remove the connected parts. Fitting the new part NOTE! Before ﬁtting the new part, read chapter (1.15 Repair methods) thoroughly. Copyright © 2010...
Page 147 3.1 Replacing the roof skin 18. Fasten the front of the roof skin to the underwindscreen rib using 10 self-piercing rivets (Ø 3.9x7.0). NOTE! Insert the new self-piercing rivets next to the old rivet holes. 19. Fasten the roof skin externally to the vehicle ﬂanks using 10x2 self-piercing rivets (Ø...
Page 148 3.1 Replacing the roof skin 20. Fasten the roof skin internally to the A-pillars using 6x2 self-piercing rivets (Ø 4.8x7.5 p/n 81126900). Caution! The high strength A-pillar reinforcements in area (A) must only be fastened with high strength structural rivets. NOTE! Insert the new self-piercing rivets next to the old rivet holes.
Page 149 3.1 Replacing the roof skin 22. Fasten the roof skin to the vehicle ﬂank in correspondence with the C-pillars using 4x2 M6 screws. Caution! Do not reuse the screws removed previously. See paragraph (1.11.3 Screw connections). 23. Use the Avdel FPM-35 gun to apply 2x2 self- piercing rivets (Ø...
Page 150 3.1 Replacing the roof skin 25. Weld the roof skin to the underwindscreen rib at to the original weld points (passenger compartment interior/exterior). 26. Weld the roof skin to the A-pillars at the original weld points. Copyright © 2010...
Page 151 3.1 Replacing the roof skin 27. Weld the roof skin to the C-pillars at the original weld points. Apply new corrosion inhibitor to the entire repair area and then apply a primer coat. 28. Reapply the beads of mastic removed previously from the windscreen adhesive bonding area.
Page 152: Reﬁt The Fender (See Chapter
3.1 Replacing the roof skin 29. Reapply all the spots of mastic removed previously (rear rain gutter area/interior of C-pillars). Danger! Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive! Wear breathing protection, protective gloves and safety glasses.
Page 153 3.2 Replacing the windscreen support rib and the windscreen valence cross-member Preliminary Remove the connected parts (dashboard, interior trim, windows, doors, lateral seals, front lid and relative hinges, rear lid and procedures relative hinges). Remove the fender (see chapter 2.1). Remove the roof skin (see chapter 3.1).
Page 154 3.2 Replacing the windscreen support rib and the windscreen valence cross-member Repair sequence Removing the old part 1. Remove the beads of mastic from the lower part of the underwindscreen rib and the mastic joining the rib itself to the windscreen valence cross-member. Danger! Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive!
Page 155 3.2 Replacing the windscreen support rib and the windscreen valence cross-member 3. Sand the exterior sections of weld joining to the underwindscreen rib. NOTE! Do not remove any other material from the front ﬁrewall. 4. Sand the sections of weld joining the underwindscreen rib and the windscreen valence cross-member.
Page 156 3.2 Replacing the windscreen support rib and the windscreen valence cross-member 5. Sand the sections of weld joining the underwindscreen rib and the underwindscreen covering. 6. Remove the 3x2 structural rivets at the ends of the windscreen valence cross-member fastening the part to the two front shock towers.
Page 157 3.2 Replacing the windscreen support rib and the windscreen valence cross-member 7. Sand the weld beads joining the windscreen valence cross-member and the two front shock towers. NOTE! Do not remove any other material from the two shock towers. Fitting the new part 8.
Page 158 3.2 Replacing the windscreen support rib and the windscreen valence cross-member 9. Fit the underwindscreen rib against the windscreen valence cross-member. 10. Tack the underwindscreen rib to both the windscreen valence cross-member and the underwindscreen covering. Fitting the new part NOTE! Before ﬁtting the new part, read chapter (1.15 Repair methods) thoroughly.
Page 159 3.2 Replacing the windscreen support rib and the windscreen valence cross-member 12. Weld the windscreen valence cross-member to the two front shock towers at the original weld points. 13. Weld the underwindscreen rib to the underwindscreen covering at the original weld points. Copyright ©...
Page 160 3.2 Replacing the windscreen support rib and the windscreen valence cross-member 14. Weld the underwindscreen rib to the front ﬁrewall at the original weld points. 15. Weld the windscreen valence cross-member to the front ﬁrewall at the original weld points. Copyright ©...
Page 161 3.2 Replacing the windscreen support rib and the windscreen valence cross-member 16. Weld the windscreen valence cross-member to the underwindscreen rib at the original weld points. Apply new corrosion inhibitor to the entire repair area and then apply a primer coat. 17.
Page 162: Reﬁt The Roof Skin (See Chapter
3.2 Replacing the windscreen support rib and the windscreen valence cross-member 18. Reﬁt the roof skin (see chapter 3.1). 19. Reﬁt the fender (see chapter 2.1). Reﬁt connected parts. Check the clearance dimensions, rework if necessary. Remove connected parts for subsequent painting. Copyright ©...
Page 163 3.3 Replacing the complete vehicle ﬂank Preliminary Remove the connected parts (dashboard, interior trim, windows, doors, lateral seals, front lid and relative hinges, rear lid and procedures relative hinges) Remove the fender (see chapter 2.1) Remove the fender mounting (see chapter 2.2) Remove the roof skin (see chapter 3.1) Remove the rear spoiler (see chapter 4.1) Place the vehicle on the vehicle bench.
Page 164 3.3 Replacing the complete vehicle ﬂank Repair sequence Removing the old part 1. Using the AVDEL gun with the 45 mm C frame, remove the rivets from the front pillar. NOTE! Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
Page 165 3.3 Replacing the complete vehicle ﬂank 3. Using the AVDEL gun with the 45 mm C frame, remove the rivets in correspondence with the lower rear bumper reinforcement and the lateral crash reinforcement. NOTE! Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
Page 166 3.3 Replacing the complete vehicle ﬂank 5. Remove the beads of mastic and foam from the upper ﬂank connector cross-members. Danger! Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive! Wear breathing protection, protective gloves and safety glasses.
Page 167 3.3 Replacing the complete vehicle ﬂank 7. Using the AVDEL gun with the 100 mm C frame, remove the rivets from the upper cross-members. NOTE! Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
Page 168 3.3 Replacing the complete vehicle ﬂank 9. Use a 10 mm wrench to remove the M6 nut fastening the vehicle ﬂank to the rear screen bulkhead substructure. 10. Sand the welds joining the vehicle ﬂank with the rear screen bulkhead substructure. NOTE! Take care not to remove any other material from the rear screen bulkhead substructure.
Page 169 3.3 Replacing the complete vehicle ﬂank 11. Sand the four weld spots joining the vehicle ﬂank and the rear screen bulkhead. 12. Remove beads sealant mastic correspondence with the front sill pillar. Danger! Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive! Wear breathing protection, protective gloves and safety glasses.
Page 170 3.3 Replacing the complete vehicle ﬂank 13. Sand the weld beads joining the vehicle ﬂank with the upper casting of the front sill pillar. Caution! Take the utmost care not to damage the die- cast joints. Check that the front sill pillar die-cast joints are free from cracks.
Page 171 3.3 Replacing the complete vehicle ﬂank 15. Remove the 4 self-piercing rivets in the inner area of the rear lid in correspondence with the two brackets fastened to the rear trellis. NOTE! Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
Page 172 3.3 Replacing the complete vehicle ﬂank 17. Remove the 2 fastener rivets joining the vehicle ﬂank and the rear ﬂank connector cross-member. NOTE! Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use. 18.
Page 173 3.3 Replacing the complete vehicle ﬂank 19. Sand any joint weld beads between the vehicle ﬂank and the upper casting of the rear sill pillar (rear lid area). Caution! Take the utmost care not to damage the die- cast joints. Check that the rear sill pillar die-cast joints are free from cracks.
Page 174 3.3 Replacing the complete vehicle ﬂank 21. Remove the 4 self-piercing rivets joining the vehicle ﬂank with the lateral reinforcement. NOTE! Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use. 22.
Page 175 3.3 Replacing the complete vehicle ﬂank 23. Remove beads sealant mastic correspondence with the rear sill pillar (interior of passenger compartment). Danger! Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive! Wear breathing protection, protective gloves and safety glasses.
Page 176 3.3 Replacing the complete vehicle ﬂank 25. Check that the front fender mounting bracket is not damaged. If necessary, adjust the gap from the sill wall to the exterior of the bracket to the correct value of 115 mm. 115 mm 26.
Page 177 3.3 Replacing the complete vehicle ﬂank Fitting the new part 27. Fit the vehicle ﬂank in its seat. Warning! This operation must be carried out with the assistance of another worker, as the size of the vehicle ﬂank makes is difﬁcult to position correctly.
Page 178 3.3 Replacing the complete vehicle ﬂank 29. Fit the 3 M8 screws onto the rear pillar. Caution! Do not reuse the screws removed previously. See paragraph (1.11.3 Screw connections). 30. Fit the external tower and the relative jigs to ensure that the vehicle ﬂank is positioned correctly.
Page 179 3.3 Replacing the complete vehicle ﬂank Fitting the new part NOTE! Before ﬁtting the new part, read chapter (1.15 Repair methods) thoroughly. 31. Tighten the 5 M8 screws applied previously. 32. Fasten the vehicle ﬂank to the rear screen bulkhead substructure with an M6 nut.
Page 180 3.3 Replacing the complete vehicle ﬂank 33. Using the AVDEL FPM-35 gun, fasten the vehicle ﬂank to the front and rear trellises with 5 self-piercing rivets (Ø 3.9x7.0 p/n 81126700). NOTE! Insert the new self-piercing rivets next to the old rivet holes. 34.
Page 181 3.3 Replacing the complete vehicle ﬂank 35. Fasten the vehicle ﬂank to the lateral reinforcement with 4 self-piercing rivets (Ø 3.9x7.0). NOTE! Insert the new self-piercing rivets next to the old rivet holes. 36. Fasten the vehicle ﬂank to the A-pillar with 22 self- piercing rivets (Ø...
Page 182 3.3 Replacing the complete vehicle ﬂank 37. Fasten the vehicle ﬂank to the kickplate (lower part of door surround) with 22 self-piercing rivets (Ø 3.9x7.0). Caution! The high strength A-pillar reinforcements must only be fastened with high strength structural rivets. NOTE! Insert the new self-piercing rivets next to the old rivet holes.
Page 183 3.3 Replacing the complete vehicle ﬂank NOTE! Check that the vehicle ﬂank is correctly ﬁtted onto the upper reinforcement cross-members. 39. Using the AVDEL gun with the 100 mm C-frame, fasten the vehicle ﬂank to the upper reinforcement cross- members with 8x2 self-piercing rivets (Ø 4.8x7.5). NOTE! Insert the new self-piercing rivets next to the old rivet holes.
Page 184 3.3 Replacing the complete vehicle ﬂank 41. Weld the vehicle ﬂank to the upper casting of the front sill pillar at the original weld points. 42. Insert the 4 self-piercing rivets (Ø 3.9x7.0) in the inner area of the rear lid in correspondence with the two brackets fastened to the rear trellis.
Page 185 3.3 Replacing the complete vehicle ﬂank 43. Weld the vehicle ﬂank to the upper casting of the rear sill pillar at the original weld points (rear lid area). 44. Fasten the rear diagonal brace by welding the ends at the original weld points. Copyright ©...
Page 186 3.3 Replacing the complete vehicle ﬂank 45. Weld the vehicle ﬂank to the upper casting of the rear sill pillar at the original weld points (passenger compartment interior). 46. Weld the vehicle ﬂank to the upper reinforcement cross-members at the original weld points. Copyright ©...
Page 187 3.3 Replacing the complete vehicle ﬂank 47. Weld the vehicle ﬂank to the rear screen bulkhead with 4 spot welds. Apply new corrosion inhibitor to the entire repair area and then apply a primer coat. 48. Reapply the beads of sealant mastic in the area surrounding the air intake and the rear screen (interior/exterior of passenger compartment).
Page 188 3.3 Replacing the complete vehicle ﬂank 49. Reapply beads sealant mastic correspondence with the upper casting of the rear sill pillar (interior/exterior of passenger compartment). Danger! Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive! Wear breathing protection, protective gloves and safety glasses.
Page 189: Reﬁt The Fender Mounting (See Chapter
3.3 Replacing the complete vehicle ﬂank 51. Reapply the beads of sealant mastic on the upper reinforcement cross-members. Danger! Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive! Wear breathing protection, protective gloves and safety glasses.
Page 190 3.4 Replacing the lateral crash reinforcement Preliminary Remove connected parts (dashboard, interior trim, windows, doors, lateral seals, front lid and relative hinges, rear lid and procedures relative hinges) Remove the fender (see chapter 2.1) Remove the fender mounting (see chapter 2.2) Remove the roof skin (see chapter 3.1) Remove the complete vehicle ﬂank (see chapter 3.3) Place the vehicle on the vehicle bench.
Page 191 3.4 Replacing the lateral crash reinforcement Repair sequence Removing the old part 1. Use a 13 mm wrench to remove the 5 M8 fastener screws joining the lateral crash reinforcement, the rear sill pillar and the extruded elements (A). NOTE! When removing the screws, take the utmost care not to let them fall into the rear door pillar.
Page 192 3.4 Replacing the lateral crash reinforcement Fitting the new part 3. Fasten the lateral crash reinforcement to the rear sill pillar and to the extruded elements (A) with 5 M8 screws. Caution! Do not reuse the screws removed previously. See paragraph (1.11.3 Screw connections). 4.
Page 193 3.4 Replacing the lateral crash reinforcement 5. Reﬁt the roof skin (see chapter 3.1). 6. Reﬁt the fender mounting (see chapter 2.2). 7. Reﬁt the fender (see chapter 2.1). Reﬁt connected parts. Check the clearance dimensions, rework if necessary. Remove connected parts for subsequent painting. Copyright ©...
Page 194 3.5 Replacing the sill Preliminary Remove connected parts (interior trim, windows, lateral seals, front lid and relative hinges, procedures rear lid and relative hinges, doors) Remove the rear end module (see F458 Italia workshop manual) Remove the fender (see chapter 2.1) Remove the fender mounting (see chapter 2.2) Remove the rear spoiler (see chapter 4.1) Remove the roof skin (see chapter 3.1)
Page 195 3.5 Replacing the sill Material necessary • 9 structural rivets (Ø 4.8x9.0) • 31 structural rivets (Ø 6.4x19.2) Repair sequence Removing the old part 1. Remove the wheel bay cover plate (see chapter 2.7). Copyright © 2010...
Page 196 3.5 Replacing the sill 2. Cut the sill near the weld beads joining to the torque box, the upper diagonal brace, the fuel tank cross- member and the semi-ﬂoorpan. Caution! Work with the utmost caution to prevent damaging the internal diagonal braces connected to the centre tunnel, the upper diagonal brace and the torque box.
Page 197 3.5 Replacing the sill 4. Sand the joint weld beads between the sill, the semi- ﬂoorpan and the diagonal braces connecting to the centre tunnel. NOTE! Do not remove any other material from the diagonal braces connecting to the centre tunnel. 5.
Page 198 3.5 Replacing the sill 6. Remove the 6 structural fastener rivets joining the front sill pillar and the torque box (interior/exterior of passenger compartment). NOTE! Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
Page 199 3.5 Replacing the sill 8. Sand the joint weld beads between the sill and the reinforcement (A). NOTE! Do not remove any other material from the torque box/centre tunnel reinforcement and from the torque box. 9. Remove the beads of sealant mastic in correspondence with the weld beads in the underbody between the sill, the torque box and the reinforcement (A).
Page 200 3.5 Replacing the sill 10. Sand the joint weld beads in the underbody between the sill, the torque box and the reinforcement (A). NOTE! Do not remove any other material from the reinforcement (A) and from the torque box. 11. Sand the internal and external joint weld beads between the sill and the upper diagonal brace.
Page 201 3.5 Replacing the sill 12. Remove the structural fastener rivets joining the sill and the internal B-pillar bracing. NOTE! Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use. 13.
Page 202 3.5 Replacing the sill 14. Gradually sand the joint weld beads between the sill connector cross-member and the sill itself. NOTE! Do not remove any other material from the sill connector cross-member. NOTE! The facilitate the operation described above, remove the external bracing. 15.
Page 203 3.5 Replacing the sill 16. Remove the 8 structural fastener rivets (Ø 6.4x19.2) in the underbody joining the sill, the lower extruded element (C) and the sill connector cross-member. NOTE! Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use.
Page 204 3.5 Replacing the sill 18. Sand the remaining weld beads in the underbody to facilitate removal of the sill. Fitting the new part 19. Fit the external tower, the mount the sill in the jig. Prepare the weld area (see chapter 1.14). Copyright ©...
Page 205 3.5 Replacing the sill NOTE! Check that the two castings of the A-pillar are ﬁtted correctly into the torque box and the upper diagonal brace. Check that the semi-ﬂoorpan is ﬁtted correctly. Fitting the new part NOTE! Before ﬁtting the new part, read chapter (1.15 Repair methods) thoroughly.
Page 206 3.5 Replacing the sill 21. Tack the sill to the sill connector cross-member and to the fuel tank cross-member (vehicle interior/ exterior). Caution! This operation must only be performed with the two cross-members mounted in the jig. NOTE! Check that the upper casting of the B-pillar is ﬁtted correctly into the fuel tank cross-member.
Page 207 3.5 Replacing the sill 23. Weld the front sill pillar to the torque box at the original weld points (interior/exterior of passenger compartment). 24. Fasten the front sill pillar and the torque box (interior/ exterior of passenger compartment) with 6 structural rivets (Ø...
Page 208 3.5 Replacing the sill 25. Weld the sill to the torque box and to the reinforcement (A) at the original weld points in the underbody. 26. Weld the rear sill pillar to the fuel tank cross-member at the original weld points. Copyright ©...
Page 209 3.5 Replacing the sill 27. Weld the sill to the upper diagonal brace at the original interior and exterior weld points. 28. Weld the sill to the reinforcement (A) at the original weld points. Copyright © 2010...
Page 210 3.5 Replacing the sill 29. Weld the sill tubular element to the semi-ﬂoorpan and to the diagonal braces connecting to the centre tunnel at the original weld points. 30. Fasten the semi-ﬂoorpan to the sill tubular element, starting at the bottom and working upward, with 9 structural rivets (Ø...
Page 211 3.5 Replacing the sill 31. Weld the sill to the sill connector cross-member (vehicle interior/exterior) at the original weld points. Apply new corrosion inhibitor to the entire repair area. Caution! Remove the jigs retaining the sill only after the welds have cooled. 32.
Page 212 3.5 Replacing the sill 33. Weld the lower extruded element (C) to the sill and to the sill connector cross-member at the original weld points. 34. Fasten the lower extruded element (C) to the sill and to the sill connector cross-member with 8 structural rivets (Ø...
Page 213 3.5 Replacing the sill 35. Fit the external bracing and weld to the sill. Reapply corrosion inhibitor to the new weld beads. 36. Fit the internal bracing and weld to the sill. Copyright © 2010...
Page 214 3.5 Replacing the sill 37. Fasten the internal and external bracing to the sill with 17 structural rivets (Ø 6.4x19.2). 38. Fit the front covering, with the two holes (D) on the covering itself aligned with the two threaded holes in the front sill pillar.
Page 215 3.5 Replacing the sill 39. Weld the front covering to the sill in correspondence with the holes in the covering itself. Reapply corrosion inhibitor to the weld beads between the two bracings. 40. Fit the rear covering, bringing it up against the rear sill pillar.
Page 216 3.5 Replacing the sill 41. Weld the rear covering to the sill in correspondence with the holes in the covering itself. 42. Fit the front ﬂank mounting bracket as shown in the diagram aside. 32 mm 129.5 mm 26 mm 11 mm Copyright ©...
Page 217 3.5 Replacing the sill 43. Weld the front ﬂank mounting bracket to the sill and to the external bracing. 44. Fit the A-pillar ﬂange against the front sill pillar, with the notch in the ﬂange over the lower sill pillar weld.
Page 218 3.5 Replacing the sill 45. Weld the A-pillar ﬂange to the sill and to the extruded hinge mounts (E) on the sill. Apply new corrosion inhibitor to the entire repair area and then apply a primer coat. 46. Reapply the beads of mastic sealant removed previously.
Page 219 3.5 Replacing the sill 47. Reﬁt the wheel bay cover plate (see chapter 2.7) 48. Reﬁt the subframe connector extruded element (see chapter 3.8) 49. Reﬁt the rear shock tower casting (see chapter 3.9) 50. Reﬁt the rear ﬁrewall and mountings (see chapter 3.6) 51.
Page 220 3.6 Replacing the rear ﬁrewall and mountings Preliminary Remove connected parts (interior trim, windows, lateral seals, rear lid and relative hinges, doors) procedures Remove the rear end module (see F458 Italia workshop manual) Place the vehicle on the vehicle bench. Replacement parts •...
Page 221 3.6 Replacing the rear ﬁrewall and mountings Repair sequence Removing the old part 1. Remove the beads of mastic sealant on the upper portion of the rear ﬁrewall (passenger compartment interior). Danger! Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive! Wear breathing protection, protective gloves and safety glasses.
Page 222 3.6 Replacing the rear ﬁrewall and mountings 3. Use a hex headed wrench (Ø 4.0) to remove the 16 M6 fastener screws joining the ﬁrewall and the rear bulkhead. 4. Remove the threaded fastener rivets (M6x21.5) joining the rear ﬁrewall and the fuel tank cross- member.
Page 223 3.6 Replacing the rear ﬁrewall and mountings 5. Remove the structural rivets fastening the rear ﬁrewall (engine area). NOTE! Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use. 6.
Page 224 3.6 Replacing the rear ﬁrewall and mountings 7. Remove the structural fastener rivets joining the ﬁrewall and the relative mountings. NOTE! Retrieve all the rivets, using a magnet if necessary, as any remaining rivets will cause noise when the vehicle is in use. 8.
Page 225 3.6 Replacing the rear ﬁrewall and mountings Fitting the new part 9. Fit the RH and LH ﬁrewall mountings up against the sill tubular elements and tack in position. Prepare the weld area (see chapter 1.14). 10. Fit the rear ﬁrewall in the seat, bringing it up against the relative mountings.
Page 226 3.6 Replacing the rear ﬁrewall and mountings Fitting the new part NOTE! Before ﬁtting the new part, read chapter (1.15 Repair methods) thoroughly. 11. Fasten the ﬁrewall to the sill connector cross- member with 16 structural rivets (Ø 4.8x10.0). 12. Fasten the back of the ﬁrewall (engine area) with 10 structural rivets (Ø...
Page 227 3.6 Replacing the rear ﬁrewall and mountings 13. Weld the RH and LH ﬁrewall mountings to the rear sill pillars at the original weld points. 14. Fasten the ﬁrewall to the relative RH and LH mountings with 2 structural rivets (Ø 4.8x10.0). Copyright ©...
Page 228 3.6 Replacing the rear ﬁrewall and mountings 15. Fasten the ﬁrewall to the fuel tank cross-member with 8 structural rivets (Ø 4.8x10.0). 16. Fasten the ﬁrewall to the centre of the fuel tank cross-member with 6 threaded rivets (M6x21.5). Copyright © 2010...
Page 229 3.6 Replacing the rear ﬁrewall and mountings 17. Fasten the rear bulkhead to the ﬁrewall with 16 M6 screws. Caution! Do not reuse the screws removed previously. See paragraph (1.11.3 Screw connections). Reapply corrosion inhibitor to the welds on the RH and LH ﬁrewall mountings and apply a coat of primer to the repair areas.
Page 230 3.6 Replacing the rear ﬁrewall and mountings 19. Reapply the beads of sealant mastic on the perimeter of the rear ﬁrewall (engine area). Danger! Danger of poisoning due to fume inhalation! Risk of injury from skin or eye contact with adhesive! Wear breathing protection, protective gloves and safety glasses.
Page 231 3.7 Replacing the fuel tank cross-member Preliminary Remove connected parts (interior trim, rear screen, lateral seals, rear lid and relative hinges) procedures Remove the rear end module (see F458 Italia workshop manual) Remove the rear ﬁrewall (see chapter 3.6) Remove the lateral ﬁrewall mountings (see chapter 3.6) Place the vehicle on the vehicle bench.
Page 232 3.7 Replacing the fuel tank cross-member Repair sequence Removing the old part 1. Use a 13 mm wrench to remove the 8 screws fastening the mountings (A) to the fuel tank cross- member. 2. Use a 13 mm wrench to remove the 8 screws fastening the internal tubular elements.
Page 233 3.7 Replacing the fuel tank cross-member 3. Cut the fuel tank cross-member near the die-cast joints on the rear sill pillars. Caution! Take the utmost care not to damage the die- cast joints. Check that the rear sill pillar die-cast joints are free from cracks.
Page 234 3.7 Replacing the fuel tank cross-member Fitting the new part 5. Mount the fuel tank cross-member in the jig. Prepare the weld area (see chapter 1.14). Fitting the new part NOTE! Before ﬁtting the new part, read chapter (1.15 Repair methods) thoroughly. 6.
Page 235 3.7 Replacing the fuel tank cross-member 7. Weld the fuel tank cross-member to the casting joints on the rear sill pillars. Caution! Remove the jig retaining the fuel tank cross- member only after the welds have cooled. Apply new corrosion inhibitor to the entire repair area and then apply a primer coat.
Page 236 3.7 Replacing the fuel tank cross-member 9. Fasten the internal tubular elements removed previously with 8 M8 screws. Caution! Do not reuse the screws removed previously. See paragraph (1.11.3 Screw connections). 10. Reﬁt the lateral ﬁrewall mountings (see chapter 3.6). 11.
Page 237 3.8 Replacing the subframe connector extruded section Preliminary Remove connected parts (complete interior, rear lid and relative hinges, lights, bumper and rear grilles) procedures Remove the rear end module (see F458 Italia workshop manual) Remove the rear spoiler (see chapter 4.1) Remove the roof skin (see chapter 3.1) Remove the complete vehicle ﬂank (see chapter 3.3) Remove the lateral crash reinforcement (see chapter 3.4)
Page 238 3.8 Replacing the subframe connector extruded section Repair sequence Removing the old part 1. Cut the lateral crash reinforcement tubular element, the rear pillar reinforcement and the suspension casting reinforcement in the area next to the weld beads. Caution! Take the utmost care not to damage the casting joints on the rear sill pillar.
Page 239 3.8 Replacing the subframe connector extruded section Fitting the new part 3. Mount the subframe connector extruded element in the jig. Prepare the weld area (see chapter 1.14). Fitting the new part NOTE! Before ﬁtting the new part, read chapter (1.15 Repair methods) thoroughly.
Page 240 3.8 Replacing the subframe connector extruded section 5. Fit the rear pillar reinforcement in the relative seats on the lateral crash reinforcement tubular element and the subframe connector extruded element and tack. 6. Check that the part is correctly positioned then weld the lateral crash reinforcement tubular element to the sill and to the subframe connector extruded element at the original weld points.
Page 241 3.8 Replacing the subframe connector extruded section 7. Weld the rear pillar reinforcement to the sill and to the lateral crash reinforcement at the original weld points. Apply new corrosion inhibitor to the entire repair area. 8. Fit the suspension casting reinforcement in the seat between the two extruded elements ﬁtted previously.
Page 242 3.8 Replacing the subframe connector extruded section 9. Weld the suspension casting reinforcement to the subframe connector extruded element and to the upper external diagonal brace at the original weld points. Caution! Remove the jig retaining the subframe connector extruded element only after the welds have cooled.
Page 243: Reﬁt The Front/Rear Lateral Trellises (See Chapter
3.8 Replacing the subframe connector extruded section 11. Weld the rear bracket (A) to the subframe connector extruded element and to the two extruded elements ﬁtted previously. 12. Reﬁt the front/rear lateral trellises (see chapter 3.10) 13. Reﬁt the lateral crash reinforcement (see chapter 3.4) 14.
Page 244 3.8 Replacing the subframe connector extruded section Reﬁt connected parts. Check the clearance dimensions, rework if necessary. Remove connected parts for subsequent painting. Copyright © 2010...
Page 245 3.9 Replacing casting for rear shock tower Preliminary Remove connected parts (complete interior, rear lid and relative hinges, lights, bumper and rear grilles) procedures Remove the rear end module (see F458 Italia workshop manual) Remove the rear spoiler (see chapter 4.1) Remove the roof skin (see chapter 3.1) Remove the complete vehicle ﬂank (see chapter 3.3) Remove the front/rear lateral trellises (see chapter 3.10)
Page 246 3.9 Replacing casting for rear shock tower Repair sequence Removing the old part 1. Cut the upper external diagonal brace near the weld beads with the die-cast sill joint. Caution! When making separating cuts, take the utmost care not to damage the casting joints. Check the location of any internal cross- member reinforcement on the new part in order to cut correctly.
Page 247 3.9 Replacing casting for rear shock tower 3. Sand the sections of joint weld between the upper external diagonal brace and the suspension casting reinforcement. NOTE! Do not remove any other material from the upper external diagonal brace. 4. Use a 13 mm wrench to remove the 4 M8 screws fastening the internal tubular element.
Page 248 3.9 Replacing casting for rear shock tower 5. Grind the joint weld beads between the upper external diagonal brace and the die-cast sill joint. Caution! Take the utmost care not to damage the die- cast sill joint. If the event of damage, the sill must be replaced (see chapter 3.5).
Page 249 3.9 Replacing casting for rear shock tower Fitting the new part 7. Mount the casting for the rear shock tower in the jig. Prepare the weld area (see chapter 1.14). Fitting the new part NOTE! Before ﬁtting the new part, read chapter (1.15 Repair methods) thoroughly.
Page 250 3.9 Replacing casting for rear shock tower 9. Fit the upper external diagonal brace against the relative seat on the die-cast rear sill pillar joint and tack in position. Check that the upper external diagonal brace is correctly positioned. 10. Fasten the upper external diagonal brace to the die- cast sill joint with 2 structural rivets (Ø...
Page 251 3.9 Replacing casting for rear shock tower 11. Weld the upper external diagonal brace to the die- cast sill joint at the original weld points. 12. Weld the upper external diagonal brace to the casting for the rear shock tower at the original weld points. Caution! Remove the jig retaining the casting for the rear shock tower only after the welds have cooled.
Page 252 3.9 Replacing casting for rear shock tower 13. Reﬁt the front/rear lateral trellises (see chapter 3.10) 14. Reﬁt the complete vehicle ﬂank (see chapter 3.3) 15. Reﬁt the rear spoiler (see chapter 4.1) 16. Reﬁt the roof skin (see chapter 3.1) 17.
Page 253 3.10 Replacing the rear lateral trellis Preliminary Remove connected parts (dashboard, interior trim, windows, doors, lateral seals, front lid and relative hinges, rear lid and procedures relative hinges) Remove the roof skin (see chapter 3.3) Remove the complete vehicle ﬂank (see chapter 3.5) Place the vehicle on the vehicle bench.
Page 254 3.10 Replacing the rear lateral trellis Repair sequence Removing the old part NOTE! The following procedures may be performed both with the rear end module installed or removed. 1. Sand the weld points on the rear trellis. NOTE! Do not remove any other material from the rear trellis.
Page 255 3.10 Replacing the rear lateral trellis NOTE! When working with the rear subframe module installed, remove the M8 screw (A) and the 2 M6 screws (B) fastening the lateral trellis to the rear subframe. 3. Sand the weld points between the connecting brackets and the rear pillar reinforcement.
Page 256 3.10 Replacing the rear lateral trellis Fitting the new part 4. Mount the lateral trellis in the jig. Prepare the weld area (see chapter 1.14) 5. Fit the trellis connector in the relative seats on the rear pillar reinforcement. Copyright © 2010...
Page 257 3.10 Replacing the rear lateral trellis Fitting the new part NOTE! Before ﬁtting the new part, read chapter (1.15 Repair methods) thoroughly. 6. Weld the lateral trellis at all the original weld points. 7. Position the bracket (C) (p/n 81649700 RH / p/n 81649800 LH) 90 mm from the edge of the extruded section (D).
Page 258 3.10 Replacing the rear lateral trellis 8. Fasten the bracket (C) to the extruded section (D) with four 15 mm lengths of weld. 9. Fit the rear bracket (E) (p/n 81583200 RH / p/n 81583300 LH), centring with the seat on the bushing (F).
Page 259 3.10 Replacing the rear lateral trellis 10. Fasten the rear bracket (E) to the extruded section (D) with four 20 mm lengths of weld. 11. Mount the bracket (G) (p/n 81952000) in the jig. NOTE! When working with the rear subframe module installed on the vehicle, use the module itself as a template for correctly ﬁtting the bracket (G).
Page 260 3.10 Replacing the rear lateral trellis 12. Fasten the bracket (G) to the front trellis with two 30 mm lengths of weld and two 10 mm lengths of weld. 13. Fit the bracket (H) (p/n 81582600 RH / p/n 81582700 LH) on the rear trellis, holding the bracket with the inner side ﬂush and at a distance of 5 mm from the 5 mm...
Page 261 3.10 Replacing the rear lateral trellis 14. Fasten the bracket (H) to the extruded section (I) with four 15 mm lengths of weld. Apply new corrosion inhibitor to the entire repair area and then apply a primer coat. NOTE! When working with the rear subframe module installed, fasten the lateral trellis to the rear subframe with 1 M8 screw (A) and 2 M6 screws (B).
Page 262 3.10 Replacing the rear lateral trellis 15. Reﬁt the complete vehicle ﬂank (see chapter 3.5). 16. Reﬁt the roof skin (see chapter 3.3). Reﬁt connected parts. Check clearances and rectify if necessary. Remove connected parts for subsequent painting. Copyright © 2010...
Page 263 4.1 Replacing the rear spoiler Preliminary Remove connected parts (rear bumper, taillights, procedures grilles and, if necessary, rear lid) Place the vehicle on the vehicle bench. Replacement parts • Rear spoiler (A) • Rear bumper mounting cross-member (B) Material necessary •...
Page 264 4.1 Replacing the rear spoiler Repair sequence Removing the old part 1. Sand the joint weld beads between the rear spoiler and the vehicle ﬂanks. NOTE! Do not remove any other material from the vehicle ﬂanks. 2. Use a 10 mm wrench to remove the 2 M6x18 fastener screws joining the spoiler and the rear bumper mounting cross-member.
Page 265 4.1 Replacing the rear spoiler 3. Use a 10 mm wrench to remove the 5 M6 fastener nuts joining the spoiler, the rear bumper mounting cross-member and the mounting bracket. 4. Clean any welding and ﬁller residue. Copyright © 2010...
Page 266 4.1 Replacing the rear spoiler Fitting the new part 5. Fit the spoiler in correspondence with the holes in the rear bumper mounting cross-member and the vehicle ﬂanks. Prepare the weld area (see chapter 1.14). Fitting the new part NOTE! Before ﬁtting the new part, read chapter (1.15 Repair methods) thoroughly.
Page 267 4.1 Replacing the rear spoiler 7. Apply and tighten the 5 M8 nuts removed previously. Caution! Do not reuse the nuts removed previously. See paragraph (1.11.3 Screw connections). Reﬁt connected parts. Check clearances on the rear lid and rectify if necessary.
Page 268 4.1 Replacing the rear spoiler 8. Weld the rear spoiler to the vehicle ﬂanks at the original weld points. Apply new corrosion inhibitor to the entire repair area and then apply a primer coat. Copyright © 2010...
Page 269 4.2 Replacing the rear bumper mounting cross-member Preliminary Remove connected parts (bumper, taillights, grilles) procedures Place the vehicle on the vehicle bench. Replacement parts • Rear bumper mounting cross-member (A) Material necessary Copyright © 2010...
Page 270 4.2 Replacing the rear bumper mounting cross-member Repair sequence Removing the old part 1. Roughly cut out the rear cross-member. 2. Sand the joint weld beads between the cross- member and the rear spars. NOTE! Do not remove any other material from the rear spars.
Page 271 4.2 Replacing the rear bumper mounting cross-member 3. Grind the welds on the rear spars. Caution! Check that the rear spars are undamaged. In the event of damage, the spars must be replaced (see chapter 4.3). Fitting the new part 4.
Page 272 4.2 Replacing the rear bumper mounting cross-member Fitting the new part NOTE! Before ﬁtting the new part, read chapter (1.15 Repair methods) thoroughly. 5. Tack and then weld the rear cross-member to the spars. Caution! Remove the jig only once the weld areas are cool.
Page 273 4.3 Replacing the rear spar Preliminary Remove connected parts (bumper, taillights, grilles) procedures Remove the rear upper trellis (see chapter 4.4) Remove the ﬂank mounting bracket (see chapter 4.5) Remove the rear cross-member (see chapter 4.2) Place the vehicle on the vehicle bench. Replacement parts •...
Page 274 4.3 Replacing the rear spar Repair sequence Removing the old part 1. Roughly cut out the rear spar. 2. Sand the joint weld beads between the spar and the rear shock tower. Caution! Take care not to damage the die-cast joints. Copyright ©...
Page 275 4.3 Replacing the rear spar 3. Grind the welds on the rear shock tower. Caution! Check that there are no cracks in the rear shock tower. In the event of damage, the entire rear end module must be replaced. Fitting the new part 4.
Page 276 4.3 Replacing the rear spar Fitting the new part NOTE! Before ﬁtting the new part, read chapter (1.15 Repair methods) thoroughly. 5. Tack and then weld the rear spar to the shock tower. Caution! Remove the jig only once the weld areas are cool.
Page 277 4.4 Replacing the rear upper trellis Preliminary Remove connected parts (bumper, taillights, grilles) procedures Remove the rear spoiler (see chapter 4.1) Place the vehicle on the vehicle bench. Replacement parts • Rear upper trellis (A) • 2 rear upper trellis support bases (B) •...
Page 278 4.4 Replacing the rear upper trellis Repair sequence Removing the old part 1. Cut the 2 support bases near the rear spars. 2. Cut the two connector brackets near the weld beads on the rear bumper mounting brackets. Copyright © 2010...
Page 279 4.4 Replacing the rear upper trellis 3. Grind all the welds in the vicinity of the cuts made previously. NOTE! Do not remove any other material from the rear spars. Fitting the new part 4. Mount the rear upper trellis in the jig. Prepare the weld area (see chapter 1.14).
Page 280 4.4 Replacing the rear upper trellis 5. Fit the rear spoiler, the rear bumper, the grilles and the taillights. Check clearances and rectify if necessary. Remove the rear spoiler, the rear bumper, the grilles and the taillights. Fitting the new part NOTE! Before ﬁtting the new part, read chapter (1.15 Repair methods) thoroughly.
Page 283 4.4 Replacing the rear upper trellis 11. Weld the connector brackets (A) joining the rear upper trellis and the rear bumper mounting brackets at the original welds. Apply new corrosion inhibitor to the entire repair area and then apply a primer coat. 12.
Page 284 4.5 Replacing the ﬂank mounting bracket Preliminary Remove connected parts (bumper, rear grilles) procedures Place the vehicle on the vehicle bench. Replacement parts • Flank mounting bracket (A) • Rear upper trellis connector bracket Material necessary • 3 x M6 screws Copyright ©...
Page 285 4.5 Replacing the ﬂank mounting bracket Repair sequence Removing the old part 1. Remove the 3 M6 fastener screws joining the ﬂank mounting bracket, the rear lateral trellis and the rear spar. 2. Sand the joint weld points between the connector bracket, the rear upper trellis and the rear spar.
Page 286 4.5 Replacing the ﬂank mounting bracket 3. Sand the joint weld beads between the ﬂank mounting bracket and the rear spar. NOTE! Do not remove any other material from the rear spars. 4. Grind all the welds sanded previously. NOTE! Do not remove any other material from the rear spar.
Page 287 4.5 Replacing the ﬂank mounting bracket Fitting the new part NOTE! Before carrying out the following operation, mount the rear lateral trellis in the jig and ensure that it is correctly positioned. If the trellis appears particularly damaged, replace the trellis itself (see chapter 3.7). 5.
Page 288 4.5 Replacing the ﬂank mounting bracket 7. Fasten the 2 M6 screws in the two holes in the rear lateral spar. Caution! Do not reuse the screws removed previously. See paragraph (1.11.3 Screw connections). 8. Tack the ﬂank mounting bracket to the rear spar. Copyright ©...
Page 289 4.5 Replacing the ﬂank mounting bracket 9. Fit the connector bracket (A) and tack in position. Check that the assembly is correctly positioned and adjust if necessary. 10. Weld the ﬂank mounting bracket to the rear spar at the original weld points. Caution! When welding the ﬂank mounting bracket, there is a risk of the spar (B) buckling as a result of...
Page 290 4.5 Replacing the ﬂank mounting bracket 11. Weld the ﬂank mounting bracket to the rear upper trellis at the original weld points. 12. Weld the connector bracket (A) at the original weld points. Apply new corrosion inhibitor to the entire repair area and then apply a primer coat.
Page 292 4.6 Replacing the upper trellis mounting bracket Preliminary Remove connected parts (rear lid) procedures Place the vehicle on the vehicle bench. Replacement parts • Upper trellis mounting bracket (A) Material necessary • 1 x M8 screw Copyright © 2010...
Page 293 4.6 Replacing the upper trellis mounting bracket Repair sequence Removing the old part 1. Remove the M8 fastener screw joining the bracket (A) and the extruded element (B). 2. Sand the weld beads between the trellis mounting bracket and the respective support base on the rear shock tower.
Page 294 4.6 Replacing the upper trellis mounting bracket Fitting the new part 4. Mount the upper trellis mounting bracket in the jig, centring with the bushing (A). Prepare the weld area (see chapter 1.14). Fitting the new part NOTE! Before ﬁtting the new part, read chapter (1.15 Repair methods) thoroughly.
Page 295 4.6 Replacing the upper trellis mounting bracket 6. Weld the upper trellis mounting bracket to the respective support base at the original weld points. Apply new corrosion inhibitor to the entire repair area and then apply a primer coat. Reﬁt connected parts. Check the clearance dimensions, rework if necessary.
Page 296 4.7 Finishing the rear end module Preliminary Place the rear end module on the vehicle bench using procedures the speciﬁc jigs. Replacement parts • Rear upper trellis (A) • 2 rear upper trellis support bases (B) • RH and LH ﬂank mounting brackets (C) •...
Page 297 4.7 Finishing the rear end module Fitting the new part Flank mounting brackets 1. Mount the ﬂank mounting brackets in the jig (see chapter 4.5.5). 2. Fasten the ﬂank mounting brackets to the rear spars with 1x2 M6 screws. Caution! Do not reuse screws removed previously.
Page 298 4.7 Finishing the rear end module NOTE! Check that the ﬂank mounting brackets are ﬂush with the spars. 3. Weld the ﬂank mounting brackets to the rear spars. Fitting the new part Rear upper trellis 4. Mount the rear upper trellis in the jig (see chapter 4.4.4).
Page 299 4.7 Finishing the rear end module 5. Weld the 2 support bases to the rear spars using the weld points on the original part as reference. 6. Weld the rear upper trellis to the two support bases. NOTE! Check that the trellis is perfectly horizontal. Copyright ©...
Page 300 4.7 Finishing the rear end module 7. Weld the connector brackets (A) between the rear upper trellis and the ﬂank mounting brackets. Fitting the new part Upper trellis mounting brackets 8. Mount the upper trellis mounting brackets in the jig (see chapter 4.6.4).
Page 301 4.7 Finishing the rear end module 9. Fit the upper trellis mountings onto the respective support bases by interference, as shown in the ﬁgure. 10. Weld the upper trellis mounting brackets to the respective support bases on both the internal and external sides of the bases.
Page 303 1 Standard times for front body shell Activity Standard times in hours 2.1 Replacing the wings 0.6 hours 2.2 Replacing the fender mounting 3.5 hours 2.3 Replacing the front lateral trellis 3.9 hours 2.4 Replacing the front cross-member 4.8 hours 2.5 Replacing the front spar 4.9 hours 2.6 Replacing the wheel bay cover plate...
Page 304 2 Standard times for central body shell Activity Standard times in hours 3.1 Replacing the roof skin 8.2 hours 3.2 Replacing the underwindscreen rib and the windscreen valence cross-member 5.1 hours 3.3 Replacing the complete vehicle side 24.2 hours 3.4 Replacing the lateral crash reinforcement 0.7 hours 3.5 Replacing the sill 46.5 hours...
Page 305 3 Standard times for rear body shell Activity Standard times in hours 4.1 Replacing the rear spoiler 2.8 hours 4.2 Replacing the rear cross-member 3.9 hours 4.3 Replacing the rear spar 4.1 hours 4.4 Replacing the rear upper trellis 3.2 hours 4.5 Replacing the ﬂank mounting bracket 1.5 hours 4.6 Replacing the upper trellis mounting bracket...
Page 306 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Adapter (900027010) 900027010 for tool AV 26300. Adaptor 95973537 (AV 3537) AV 3537 valve seat guide installer punch. Adaptor 95973604 (AV 3604) for angular AV 3604 engine timing reference tool. Adaptor 95973606 (AV 3606)
Page 307 for checking big end diameter.
Page 308 Foto Code Description California FF APERTA Italia Scaglietti Sess Fiorano Bushing (AV 3350) for upper AV 3350 pump assembly fastener screws. Calibre (ALZF 09206) 92 mm ALZF 09206 diameter for cylinder sleeves. Calibre (TLDF006108) TLDF006108 for checking valve guide wear. Extractor 95972714_1 AV 2714...
Page 309: Table Of Contents
Foto Code Description California FF APERTA Italia Scaglietti Sessant Fiorano Feeler gauge (CS 107155) for measuring CS 107155 axial connecting rod endfloat. Goniometer 95975784_2 AM 105784 (AM 105784) for setting engine timing Go/no-go gauge TLDF02060 95972060 (TLDF02060) for small end. Handle 900026300 (900026300)
Page 310 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Pressure 95971243 gauge ( 95971243) Punch (900026550) for installing 900026550 crankshaft bearing, clutch side. Punch (900026590) 900026590 mounting oil seal on front crankcase cover. Punch (900027000) mounting 900027000 cylinder head alignment dowel.
Page 311 flywheel side of crankshaft.
Page 312 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Punch 95972178 102178) 102178 for installing valve guides, Ø 7 Punch 95972692 (AV 2692) AV 2692 extracting valve guide. Screw 95973435 (AV 3435) AV 3435 goniometer connector hub (AM 105784). Screwdriver 95973002 (AV 3002)
Page 313 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Supports 95973135 (AV 3135) AV 3135 for checking camshaft (concentricity). Tensiometer (95978151) 95978151 Seem DIAPAZ. Tool (AM 107064) mounting for 107064 crankcase on AV 2621 trolley. Tool (AM 107080) 107080 for supporting head.
Page 314 Foto Code Description California FF APERTA Italia Scaglietti Sessant Fiorano Tool (AV 3843) immobilising AV 3843 camshafts, with 30 mm diam. hexagonal head. Tool (1870736000) 1870736000 for removing fuel pump ring nut. Tool (900026610) 900026610 cylinder sleeve extractor. Tool (900026970) 900026970 for cleaning head...
Page 315 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Tool 95970737 (AV 737) dial gauge measuring piston TDC. Tool 95972916 (CS 102916) cylinder 102916 sleeve projection measurement dial gauge. Tool 95972926 (AV 2926) 2926 extracting valve guides. Tool 95972955 (AV 2955) for checking 2955...
Page 316 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Tool 95973605 (AV 3605) for centring installing 3605 check valve on right and left hand cylinder banks. Tool 95973607 (AV 3607) immobilising 3607 crankshaft for damper installation (with engine in vehicle) Tool 95973838 (AV 3838)
Page 317 Tool 95974488 (CS 104488) dial gauge 104488 measuring piston T.D.C.
Page 318 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Tool 95977231 107231) 107231 for installing cylinder sleeves. Tools 95973602 (AV 3602) AV 3602 for installing water-oil pump. Torque wrench end F9x12/17 fitting (F9x12/17) Torque wrench 95973305 FACOM S.405DA (95973305) Torque wrench 95978172...
Page 320 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Trolley 95972621 (AV 2621) AV 2621 overhauling engine- gearbox assemblies Wrench (AV 6038) detaching AV 6038 delivery pipe from pump to steering box. Wrench USAGD156 (95971560) 95971560 tightening oil filter. Wrench (900026990) for variable...
Page 321 removing tapered roller bearing on cover side.
Page 322 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Centring screws 95973251 (AV 3251) 3251 for shaft-rod cluster with forks. Extractor 95972714 (AV 2714) 2714 for the differential flange. Extractor 95973045 (AV 3045) 3045 for the differential flange. Extractor 95973272 (AV 3272) for 3rd - 4th...
Page 323 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano 95973831 (AV 3831) centring 3831 pin for bevel gear pair crown installation. Plate 95973536 (AV 3536) 3536 pressure seal test. Pliers 95973612 (AV 3612) for crown pinion clearance 3612 gauge (used in conjunction with AV-...
Page 324 Punch 95973079 (AV 3079) for centring 3079 complete thrust bearing.
Page 325 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Punch 95973268 (AV 3268) for fitting 3268 the retainer washer (Ø 14 mm). Punch 95973270 (AV 3270) for fitting 3270 the retainer washer (Ø 25 mm). Ring nut (AV 8066) removing 8066 oil tank...
Page 326 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Tool (AV 3375) for replacing upper rubber 3375 bushing on gearbox housing. Tool (AV 8065) for topping 8065 up oil with F1 kit. Tool 95973070 (AV 3070) 3070 disengaging the clutch. Tool 95973080 (AV 3080)
Page 327 Foto Code Description California FF APERTA Italia Scaglietti Se Fiorano Tool 95973234 (AV 3234) for replacing lower 3234 bushing on gearbox housing (8 components) Tool 95973243 (AV 3243) for fitting assembled 3243 gearbox shafts (5 components). Tool 95973252 (AV 3252) 3252 disassembling/assembling the main shaft (4...
Page 328 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Tool 95973259 (AV 3259) 3259 for fitting roller bearing outer ring. Tool 95973260 (AV 3260) extracting/inserting 3260 gearbox housing bearing (2 components). Tool 95973261 (AV 3261) 3261 for fitting clutch shaft bearing.
Page 329 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Tool 95973265 (AV 3265) for fitting bearing and 3265 bushing on intermediate plate (4 components). Tool 95973266 (AV 3266) 3266 for checking pinion play. Tool 95973267 (AV 3267) 3267 for installing ball bushing.
Page 331 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Tool 95973276 (AV 3276) for fitting the bearing onto 3276 differential shaft with flange (2 components). Tool 95973277 (AV 3277) for fitting bearing onto 3277 differential half -shaft with flange on left- hand side.
Page 332 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Tool 95973832 (AV 3832) 3832 for fitting oil circuit seal. Tool 95973833 (AV 3833) for fitting outer roller 3833 bearing tapered ring on cover. Tool 95973834 (AV 3834) for fitting 3834 tapered roller...
Page 333 hydraulic system.
Page 334 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Tool 95976121 106121) for fitting 106121 1st and 2nd gear synchroniser sleeve. Tool 95976524 106524) for checking 106524 gap between pinion and the bearing seat. Union 95973283 (AV 3283) 3283 to keep the air under pressure.
Page 335 Wrench 95973247 (AV 3247) secondary 3247 shaft bearing retainer ring nut.
Page 336: Table Of Contents
Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Plug (AS 10723 -07) for supporting 10723 upper arm for ball joint removal. Plug (AV 3427- 3427- lower leverage surface for ball joint removal. Support 95973206 (AV 3206) 3206 for complete hub.
Page 337 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Tool 95973281 (AV 3281) leverage surface 3281 for installing Flanbloc. Tool 95973282 (AV 3282) for fitting and 3282 removing Flanbloc. Tool 95973304 (AV 3304) 3304 removing/fitting shock absorber bushing. Frame 95973307 (AV 3307) 3307...
Page 338 Foto Code Description California FF APERTA Italia Scaglietti Sessant Fiorano Tool 95978072 (AV 8072) for aligning AV 8072 the cosmetic tailpipe tips with the exhaust tailpipes Shim 95978170 (AV 8170) AV 8170 for locating the engine compartment lid window. Boring bar 95974736 (AS 4736) AS 4736...
Page 339 Foto Code Description California FF APERTA Italia Scaglietti Sessant Fiorano Dial gauge mounting 95977148 CS 7148 (CS 7148) for measuring valve seat wear. Index 95970208 105165/21 105165/21) for engine timing. Insertion tool 95972627 (AV 2627) AV 2627 for rear crankshaft seal ring Lapper 95970240...
Page 340 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Punch 95970866 (AV 865) connecting bushing. Punch 95972727 (AV 2727) installing 2727 front crankcase cover “Corteco” seal ring. Punch 95972740 (AV 2740) 2740 installing check valve. Punch 95973011 (AV 3011) installing 3011 engine...
Page 341 Punch 95973106 (AV 3106) for fitting 3106 front timing cover bearing.
Page 342 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Reamer 95974720 (US 4720) 4720 camshaft seat Shim 95973345 (AV 3345) 3345 punch AV 102178. Support 95972905 (AV 2905) 2905 polygonal wrench. Support 95974994 104994) 104994 crankcase on trolley AV 2621. Tool (AV 3287) securing...
Page 343 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Tool 95972697 (AV 2697) 2697 installing cylinder sleeves. Tool 95972882 (AV 2881) 2881 installing valve oil seal. Tool 95973546 (AV 3546- 3546- for dumper anti-rotation in vehicle. Tool 95975774 105774) 105774 installing cylinder...
Page 345 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Wrench 95972906 2906 (AV 2906) polygonal. Wrench 95973400 (AV 3400) 3400 for engine oil filter. Adaptor 95973300 (AV 3300) 3300 for tool AM106628. Base 95973415 (AV 3415) 3415 removing the bearing race from the pinion.
Page 346 onto the central housing.
Page 347 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano 95972679 (AV 2679) locating 2679 the 3rd, 4th, 5th, gearbox rods. 95972881 102881) 102881 aligning clutch plate. Punch 95972640 (AV 2640) for fitting 2640 the bearing onto the secondary shaft. Punch 95972644 (AV 2644)
Page 348 Punch 95972649 2649/1 2649/1) for fitting bushings...
Page 349 Foto Code Description California FF APERTA Italia Scaglietti Sessant Fiorano Punch 95972649 AV 2649/2 (AV 2649/2) for fitting bushings Punch 95972655 (AV 2655) AV 2655 for the primary shaft bearing. Punch 95973297 AV 3297 (AV 3297) for bushing extraction. Punch 95976629 (AM 106629) AM 106629...
Page 350 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Shim 95973414 (AV 3414) bearing 3414 location for tool AV 2622. Shim 95973418 (AV 3418) 3418 for tool AV 3275. Support 95977312_1 107312) for fitting 107312 gearbox housing onto AV 2621 trolley.
Page 351 gearbox housing.
Page 352 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Tool 95972622 (AV 2622) for fitting 2622 the bearing onto the pinion. Tool 95972629 (AV 2629) for fitting the bearing 2629 onto the central gearbox housing. Tool 95972630 (AV 2630) for fitting the bearing 2630...
Page 353 Tool 95973411 (AV 3411) 3411 spacer for tool AV2622.
Page 354 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Tool 95973418 (AV 3418) 3418 for fitting the case. Tool 95973419 (AV 3419) 3419 for centring the side cover lever. Tool 95973458 (AV 3458) for centring shaft 3458 clearance between the universal joint and the actuator.
Page 355 onto differential.
Page 356 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Tool 95976636 106636) 106636 supporting differential. Wrench 95972054 (AV 2054) 2054 for clutch shaft ring nut. Wrench 95972631 (AV 2631) for the 2631 primary shaft ring nut, differential side. Wrench 95972632 (AV 2632) 2632...
Page 357 Wrench 95973412 (AV 3412) for the intermediate 3412 ring nut on secondary shaft (3 components).
Page 358 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Wrench 95975177 105177) for fastening 105177 the primary shaft ring nut on the engine side. Tool (AV 3427-13) 3427- for fitting Flanbloc. Tool (AV 5225-2) leverage 5225-2 surface for extracting Flanbloc.
Page 359 measurement dial gauge.
Page 360 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Belt tensioner (AV 8171) setting the 8171 alternator belt tension. Boring bar 95977233 107233 107233) cylinder bank. Engine bushing installation template (AV 8169) 8169 checking alignment of rubber engine bushings. Hook (AV 3979) 3979...
Page 361 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Kit (AV 3982) AV 3982 press-fitting oil pipes on engine. Lapper 95973429 AV 3429 (AV 3429) cylinder bank. Lever 95973433 AV 3433 (AV 3433) for fitting timing chain Punch (900027260) mounting 6 900027260 diameter...
Page 362 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Shield (AV 3983) intake 3983 header cover. Tool (AM 107256) 107256 installing half cones. Tool (AV 3374) 3374 installing oil seal on valve. Tool (AV 3978) 3978 for timing reference Tool (AV 3984) aligning...
Page 364 Foto Code Description California FF APERTA Italia Scaglietti Sess Fiorano Tool (900027360) for immobilising 900027360 crankshaft for removing/refitting dumper. Tool 95972885 (AV 2885) AV 2885 for fitting oil sump bearing. Tool 95973434 (AV 3434) for fitting O-rings AV 3434 on crankcase and lower crankcase shell fastener stud bolts.
Page 365 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Tool (900026250) 900026250 for complete clutch mount. Tools 95973218 (AV 3218) AV 3218 for fitting the seal ring (3 components). 354 mm template (AV 8168) for setting correct AV 8168 distance between chassis and...
Page 366 Tool 95977566 (AS 107566) 107566 for removing the oil sump.
Page 367 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Trolley 95977565 107565) removing 107565 engine / gearbox / subframe assembly. Wrench 95978175 (AV 8175) tightening 8175 fuel pump filter retainer ring. Wrench 95978176 (AV 8176) 8176 tightening fuel level sensor.
Page 368 kinematics L=1100.
Page 369 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano 95977570 107570) 107570 support for kinematics L=806. Fastener brackets for safety retainers 95978184 (AV 8184) raised 8184 vehicle anti- tipping retention for runway type car lifts. Feeler gauge 95978181 (AV 8181) checking 8181 Rear Roof...
Page 370 95978178 (AV 8178) 8178 for RHT kinematics.
Page 371 Foto Code Description California FF APERTA Italia Scaglietti Fiorano Safety retainers 95978183 (AV AV 8183 8183) vehicle anti- tipping retention. Separator tool 95978179 (AV 8179) AV 8179 adjusting the Rear Roof shell striker plates Template kit (A7082600 - A7082600/TIN A7082600 - - A456) A7082600/TIN (see repair...
Page 372 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Trolley 95977571 (AS 107571) 107571 support for complete RHT. Brackets for fastening to engine and clutch housing shims 8252 95978252 (AV 8252) for hoisting engine. Engine retainer bracket for gearbox removal 8254 95978254 (AV...
Page 373 extension elements AV 8177 for connection to an exhaust gas extraction system. Template 95978257 (AV 8257) 8257 fitting flexible exhaust pipe.
Page 374 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Trolley 95977572 (AS 107572) to be used together with trolley AS 107572 107565 for removing/refitting gearbox from and into vehicle. Mounting bracket for vehicle safety retainers for lifting 95978251 8251 (AV 8251) lifting vehicle on vehicle lift.
Page 375 Foto Code Description California FF APERTA Italia Scaglietti Sessanta Fiorano Template kit (A7082900 A7082900 - A7082900/T A7082900/T - A456) - A456 (see repair manual for aluminium bodyshell).
Page 376 Print Exit 01.01 Consultation Consulting the manual The manual is divided into sections, with each section identified by a different letter. Each section is divided into chapters, identified by the letter indicating the relative section followed by a sequential number. Each chapter is, in turn, divided into paragraphs, identified by the letter indicating the relative section, the chapter number and a sequential number, separated from the former by a point.
Page 377 Print Exit 01.02 Updates Updates The manual will be updated periodically to reflect modifications made to the vehicle and the production of new versions. ALWAYS read the Technical Notes as they may introduce more recently updated regulations and methods than those in this manual.
Page 378 Print Exit 01.03 Symbols The safety symbols given below are used to warn the operator of personal safety hazards and operational conditions which may cause damage to the vehicle, and to provide useful information concerning the operation being performed. CAUTION Failure to observe the instructions given in this note may result in serious injury to the operator and/or to persons in the immediate vicinity.
Page 379 Print Exit 01.04 Glossary Nitrogen Carbon Monoxide Carbon Dioxide Nitrogen Oxide Hydrocarbons Standard Indicates reference value Service limit Indicates the limit value beyond which a part or coupling must be serviced to bring it back within the prescribed tolerance range Right hand and/or left hand The terms right hand and/or left hand indicate the right hand and/or left-hand side of the vehicle with respect to the front of the vehicle...
Page 380 A.C. (Air Conditioning) Wheelspin control during acceleration (Antriebs Schlupf Regelung) Communication line between ECUs (Controller Area Network) Positive temperature coefficient, resistance increases as temperature increases (Positive Temperature Coefficient) Negative temperature coefficient, resistance decreases as temperature increases (Negative Temperature Coefficient) E-DIFF (Electronic Differential) (Electronic Brake force Distribution) (Electronic Control Unit)
Page 381 (Tyre Pressure Monitoring System) A system that eliminates the gap between the brake pads and discs by applying slight pressure to the brake system as soon as the accelerator pedal is released when imminent braking is expected. (Ferrari Brake Prefill)
Page 382 Manual user Manual user This publication was produced by the FERRARI Technical Service Department as an informative support tool to assist the operator in performing work on FERRARI cars. This manual is intended for expert operators with sufficient knowledge and skill to carry out all maintenance and repair operations for FERRARI cars correctly and safely.
Page 383 In addition to the guided diagnostic system, that can be implemented using the FERRARI DEIS tester, each section of the manual contains diagnostic procedures to identify malfunctions of the different components in the vehicle.
Page 384 Using tools and spare parts Using tools and original spare parts FERRARI supplies workshops authorised to repair its vehicles with specific tools to ensure that repair work is carried out correctly and safely. Carrying out any work without using specific FERRARI tools, or using alternative tools, may cause damage to relative component and/or system, voiding the warranty.
Page 385 "Power warranty handbook". For more information, contact the Ferrari Technical Service Department. Carrying out any work without using specific FERRARI tools, or using alternative tools, may cause damage to relative component and/or system, voiding the warranty. Always use original FERRARI spare parts, consulting the relative spare parts catalogue.
Page 386 02.05 Tightening torques For the fastening of main vehicle components, Ferrari has defined three tolerance classes relative to the rated torque value: The tolerance class is shown in the summary paragraphs concerning tightening torques, at the beginning of each section and/or at the beginning of each paragraph.
Page 387 Print Exit 03.01 Safety at work Prevention measures and protection devices When carrying out particularly hazardous or difficult service or repair operations, the service staff must take all precautions to prevent personal injury or damage to the vehicle. Always wear protective gloves when working on sharp or hot parts, or when handling dangerous parts. In the latter case, we recommend protecting the eyes with appropriate safety goggles.
Page 388 Print Exit 03.02 Hazards Exhaust gas Danger Precautions The engine must be kept running for certain Never run the engine in a closed space; preferably maintenance procedures. Exhaust gases contain work outdoors or use exhaust extraction systems. carbon monoxide, a highly toxic gas which may even cause death in the event of prolonged inhalation.
Page 389 Coolant Danger Precautions The cooling circuit contains fluid at high temperature Keep out of reach of children! and pressure: contact with hot coolant may cause Never dispose of coolant into the environment! severe burns. Coolant may cause irritation in the event of skin contact and is poisonous if swallowed.
Page 390 Print Exit 03.03 Dangerous emissions Exhaust system and engine Danger Precautions As the vehicle is used, the components of the exhaust Always wear insulating gloves when handling these system and the engine itself reach very high components, or wait as long as necessary for the temperatures and remain hot long after the engine components to cool.
Page 391 Print Exit 04.01 Identification and type approval labels Identification and type approval labels A - 'Do not install child seat on passenger seat' label B - Mercury warning label C - Safety standard compliance label D - VIN label (Vehicle Identification Number) E - Airbag maintenance label F - Passenger airbag warning label G - Unleaded fuel label...
Page 392 Q - TPMS system installed warning label R - Chassis number plate S - Original paintwork label...
Page 393 Print Exit 04.02 'Do not install child seat on passenger seat' warning 'Do not install child seat on passenger seat' warning A - 'Do not install child seat on passenger seat' warning...
Page 394 Print Exit 04.03 Mercury content warning Mercury content warning B - Mercury content warning...
Page 395 Print Exit 04.04 Safety standard compliance Safety standard compliance C - Safety standard compliance...
Page 396 Print Exit 04.05 V.I.N. (Vehicle Identification Number) V.I.N. (Vehicle Identification Number) D - V.I.N. (Vehicle Identification Number)
Page 397 Print Exit 04.06 Airbag maintenance Airbag maintenance E - Airbag maintenance...
Page 398 Print Exit 04.07 Passenger airbag warning Passenger airbag warning F - Passenger airbag warning...
Page 399 Print Exit 04.08 Unleaded fuel Unleaded fuel G - Unleaded fuel...
Page 400 Print Exit 04.09 Radiator containing antifreeze Radiator containing antifreeze H - Radiator containing antifreeze...
Page 401 Print Exit 04.10 Emissions control system specifications Emissions control system specifications I - Emissions control system specifications...
Page 402 Print Exit 04.11 Engine type and number Engine type and number L - Engine type and number...
Page 403 Print Exit 04.12 Assembly number Assembly number M - Assembly number...
Page 404 Print Exit 04.13 Engine and gearbox oil identification Engine and gearbox oil identification N - Engine and gearbox oil identification...
Page 405 Print Exit 04.14 Gearbox type and number Gearbox type and number O - Gearbox type and number plate...
Page 406 Print Exit 04.15 Tyre type and pressure Tyre type and pressure P - Tyre type and pressure...
Page 407 Print Exit 04.16 TPMS system installed warning TPMS system installed warning Q - TPMS system installed warning...
Page 408 Print Exit 04.17 Chassis number Chassis number R - Chassis number...
Page 409 Print Exit 04.18 Original paint Original paint S - Original paint...
Page 410 Print Exit 05.01 Performance and consumption Performance 0 to 62 mph 1.312 ft from Top speed standing start DCT gearbox < 3.4 sec 11.3 sec > 202 mph Fuel consumption (estimated figures based on tests conducted with vehicles equipped with frequently requested options.
Page 411 Print Exit 05.02 Dimensions and weights Dimensions and weights Wheelbase 104.33 in. Max. length 178.23 in. Max. width 76.26 in. Max. height 47.76 in. Front overhang 43.58 in. Rear overhang 30.31 in. Front track 65.83 in. Rear track 63.23 in. Kerb weight (DCT) 3384 lbs (with most favourable...
Page 412 Print Exit A1.01 Fluid properties Cooling circuit (1) Protective fluid with antifreeze action for monoethylene glycol-based cooling systems. 50 % Water 50 % Windscreen washer/headlight washer system Mixture of water and denatured isopropyl alcohol 50 % Glass cleaner 2 phial...
Page 413 Print Exit A1.02 Fluids and lubricants table Parts to be refilled Product Quantity Engine (1) (2) (3) 10.57 qts. PENNZOIL ULTRA™ SAE 5W-40 Gearbox and differential 4.12 qts. SHELL TRANSAXLE 75W-90 GL5 / SHELL SPIRAX S5 ATE 75W-90 Clutch system and hydraulic 8.45 qts.
Page 414 Print Exit Page 01 of 03 Pre-Delivery Inspection - PDI form Model Updated on 458 Italia March 2010 Chassis number: Dossier creation date: Job order n°: Notes: Performed Performed R.O.L. N° Description of inspection / operation: NOT OK (if NOT OK) 1.
Page 415 Page 02 of 03 Pre-Delivery Inspection - PDI form Model Updated on 458 Italia March 2010 Performed Performed R.O.L. N° NOT OK (if NOT OK) 23. - Coolant level. 24. - Power steering fluid level. 25. - Braking system fluid level.
Page 416 Page 03 of 03 Pre-Delivery Inspection - PDI form Model Updated on 458 Italia March 2010 Performed Performed R.O.L. N° NOT OK (if NOT OK) 50. - Visual inspection of fuel tanks. 51. – Visual inspection: Suspension units, etc. 52. -Visual inspection of Earth: car/engine and gearbox-chassis.
Page 417 Print Exit Page 1 of 2 Scheduled Maintenance File Model Updated on 458 Italia February 2011 Chassis number: Dossier creation date: Mileage in Job order No.: Notes: Yearly Maintenance Performed Description of procedure Notes Vehicle reception - preparation Indicator light check External visual brake inspection (pads and discs);...
Page 418 Setting the vehicle on the ground Replacing the engine oil filter Filling with engine oil Removing right hand underwindscreen shield cover to allow access to brake fluid reservoir Replacing brake fluid (every 2 years - replace more frequently if the vehicle is used in severe operating conditions) Visual inspection of power steering fluid, brake fluid, engine coolant and windscreen washer fluid levels...
Page 419 Page 2 of 2 Performed Description of procedure Notes Checking and (if necessary) replacing air filter (in the event of use in particularly dusty conditions or on roads treated with sand and/or salt, more frequent replacement is recommended) Replacing the pollen filter Replacing the airbag (every 15 years) Replacing seat belts and pretensioners (every 15 years)
Page 420 Vehicle delivery date:...
Page 421 Print Exit Page 1 of 2 Scheduled Maintenance File Model Updated on 458 Italia February 2011 Chassis number: Dossier creation date: Mileage in Job order No.: Notes: 20,000 Km (12,500 Miles) Performed Description of procedure Notes Vehicle reception - preparation Indicator light check External visual brake inspection (pads and discs);...
Page 422 Visual inspection of power steering fluid, brake fluid, engine coolant and windscreen washer fluid levels Visual inspection of pipes...
Page 423 Page 2 of 2 Performed Description of procedure Notes Checking and (if necessary) replacing air filter (in the event of use in particularly dusty conditions or on roads treated with sand and/or salt, more frequent replacement is recommended) Replacing the pollen filter Replacing the airbag (every 15 years) Replacing seat belts and pretensioners (every 15 years)
Page 424 Vehicle delivery date:...
Page 425 Print Exit Page 1 of 2 Scheduled Maintenance File Model Updated on 458 Italia February 2011 Chassis number: Dossier creation date: Mileage in Job order No.: Notes: 40,000 Km (25,000 Miles) Performed Description of procedure Notes Vehicle reception - preparation Indicator light check External visual brake inspection (pads and discs);...
Page 426 Visual inspection of power steering fluid, brake fluid, engine coolant and windscreen washer fluid levels Visual inspection of pipes...
Page 427 Page 2 of 2 Performed Description of procedure Notes Checking and (if necessary) replacing air filter (in the event of use in particularly dusty conditions or on roads treated with sand and/or salt, more frequent replacement is recommended) Replacing the pollen filter Replacing the airbag (every 15 years) Replacing seat belts and pretensioners (every 15 years)
Page 428 Vehicle delivery date:...
Page 429 Print Exit Page 1 of 2 Scheduled Maintenance File Model Updated on February 2011 Chassis number: Dossier creation date: Mileage in Job order No.: Notes: 60,000 Km (37,500 Miles) Performed Description of procedure Notes   Vehicle reception - preparation Indicator light check External visual brake inspection (pads and discs);...
Page 430 Page 2 of 2 Performed Description of procedure Notes Checking and (if necessary) replacing air filter (in the event of use in particularly dusty conditions or on roads treated with sand and/or salt, more frequent replacement is recommended) Replacing the pollen filter Replacing spark plugs (replace more frequently if the vehicle is used in severe operating conditions) Replacing the airbag (every 15 years)
Page 431 Print Exit Page 1 of 2 Scheduled Maintenance File Model Updated on February 2011 Chassis number: Dossier creation date: Mileage in Job order No.: Notes: 80,000 Km (50,000 Miles) Performed Description of procedure Notes   Vehicle reception - preparation Indicator light check External visual brake inspection (pads and discs);...
Page 432 Page 2 of 2 Performed Description of procedure Notes Checking and (if necessary) replacing air filter (in the event of use in particularly dusty conditions or on roads treated with sand and/or salt, more frequent replacement is recommended) Adjusting, cleaning, repairing or replacing ignition cables Replacing the airbag (every 15 years) Replacing seat belts and pretensioners (every 15 years)
Page 433 Print Exit Page 1 of 2 Scheduled Maintenance File Model Updated on February 2011 Chassis number: Dossier creation date: Mileage in Job order No.: Notes: 100,000 Km (62,500 Miles) Performed Description of procedure Notes   Vehicle reception - preparation Indicator light check External visual inspection of brakes (pads and discs), replace if necessary...
Page 434 Page 2 of 2 Performed Description of procedure Notes Checking and (if necessary) replacing air filter (in the event of use in particularly dusty conditions or on roads treated with sand and/or salt, more frequent replacement is recommended) Replacing the pollen filter Replacing the airbag (every 15 years) Replacing seat belts and pretensioners (every 15 years)
Page 435 Print Exit Page 1 of 2 Scheduled Maintenance File Model Updated on February 2011 Chassis number: Dossier creation date: Mileage in Job order No.: Notes: 120,000 Km (75,000 Miles) Performed Description of procedure Notes   Vehicle reception - preparation Indicator light check External visual brake inspection (pads and discs);...
Page 436 Page 2 of 2 Performed Description of procedure Notes Checking and (if necessary) replacing air filter (in the event of use in particularly dusty conditions or on roads treated with sand and/or salt, more frequent replacement is recommended) Replacing the pollen filter Replacing spark plugs (replace more frequently if the vehicle is used in severe operating conditions) Replacing the airbag (every 15 years)
Page 437 Print Exit Page 1 of 2 Scheduled Maintenance File Model Updated on February 2011 Chassis number: Dossier creation date: Mileage in Job order No.: Notes: 140,000 Km (87,500 Miles) Performed Description of procedure Notes   Vehicle reception - preparation Indicator light check External visual brake inspection (pads and discs);...
Page 438 Page 2 of 2 Performed Description of procedure Notes Checking and (if necessary) replacing air filter (in the event of use in particularly dusty conditions or on roads treated with sand and/or salt, more frequent replacement is recommended) Replacing the pollen filter Replacing the airbag (every 15 years) Replacing seat belts and pretensioners (every 15 years)
Page 439 Print Exit Page 1 of 3 Scheduled Maintenance File Model Updated on February 2011 Chassis number: Dossier creation date: Mileage in Job order No.: Notes: 160,000 Km (100,000 Miles) Performed Description of procedure Notes   Vehicle reception - preparation Indicator light check External visual brake inspection (pads and discs);...
Page 440 Page 2 of 3 Performed Description of procedure Notes Checking and (if necessary) replacing air filter (in the event of use in particularly dusty conditions or on roads treated with sand and/or salt, more frequent replacement is recommended) Adjusting, cleaning, repairing or replacing ignition cables Adjusting, cleaning, repairing or replacing air injection system components Replacing fuel injectors...
Page 441 Page 3 of 3 Performed Description of procedure Notes Service counter reset DEIS Diagnosis Adjusting idle speed Road test (vehicle test) Car wash and cleaning interiors (optional) Treating interior trim in leather (if necessary) Check for the existence of open campaigns on the ModisCS system and record the service in the service entry Procedure carried out by (Dealer): Technical Manager:...
Page 442 Print Exit A3.01 Checking engine oil level and changing engine oil and engine lubrication system filters Checking the engine oil level Always check the engine oil level with a warm engine. The oil level must be checked with the vehicle standing on a level surface and with the engine idling. The symbol shown aside is displayed on the left hand TFT display together with the message "Check engine oil level"...
Page 443 8. Screw the cap (1) back on tightly. After topping up, the "Low oil level" symbol shown aside may remain active on the left hand TFT display for a prolonged period of time. This occurs to allow the system to perform all the checks necessary. This is completely normal. 9.
Page 444 Drain the engine lubrication system ( A3.01). Remove the engine oil filter (A) with a 32 mm socket wrench fitted in the relative seat, an extension (USAG 236 1/2" L = 250mm) and a reversible ratchet. Turning counterclockwise (as indicated by the arrow), unscrew the complete engine oil filter (A). Protect the surrounding area with absorbent cloths.
Page 445 Fit the complete engine oil filter (A) correctly in the relative seat on the engine, taking care not to damage the filter during assembly. Fasten the engine oil filter (A) with a 32 mm socket wrench fitted in the relative seat, an extension (USAG 236 1/2"...
Page 446 Print Exit A3.02 Inspecting oil level and replacing Shell Transaxle 75W-90 GL5 gear oil Checking the Shell Transaxle 75W-90 GL5 gear oil level Tightening torque Class Fastening gearbox oil filler/drain plug and clutch Plug 25 Nm hydraulic fluid filler/drain plug The following procedures must be carried out exactly as described to ensure that the hydraulics are proper lubricated and function correctly.
Page 447 The gear oil must be changed at the intervals specified in the MAINTENANCE SCHEDULE. Remove the rear flat undertray section ( E3.12). Place a container under the plugs indicated in the figure to collect the oil. Undo the plugs (1) and (2) at the bottom of the gearbox housing. Pour the oil drained from the system into a container and seal it.
Page 448 Print Exit A3.03 Checking Shell DCT F-3 hydraulic clutch system fluid level Checking Shell DCT F-3 hydraulic clutch system fluid level Tightening torque Class Fastening gearbox oil filler/drain plug and clutch Plug 25 Nm hydraulic fluid filler/drain plug The following procedures must be carried out exactly as described to ensure that the hydraulics are proper lubricated and function correctly.
Page 449 Check the fluid level with the level pipe (2): the fluid must reach the upper edge of the pipe, on the limit of overflowing. If the level is too low, identify the possible causes for excessive consumption before refilling. If the level is too low (oil not overflowing), top up as follows.
Page 450 Print Exit A3.04 Checking the windscreen and headlight washer fluid level Checking the windscreen and headlight washer fluid level The windscreen/headlight washer fluid reservoir cap is located underneath the luggage compartment lid. Open the cap (A) on the windscreen/headlight washer fluid filler pipe. Check that the level of the windscreen/headlight washer fluid level is visible in the filler neck.
Page 451 Print Exit A3.05 Checking brake system fluid level Checking brake fluid reservoir level The brake fluid reservoir is located at the centre of the luggage compartment, underneath the right hand underwindscreen shield. Open and close the cover VERY CAREFULLY, as the fastener tabs are particularly fragile. Remove the cover (A) from the right hand underwindscreen shield to access the brake fluid reservoir cap, prising off at the position indicated...
Page 452 The fluid contained in the brake system is harmful in the event of contact with the eyes or skin. In the event of contact with brake fluid, rinse the affected area immediately with plenty of running water. Brake fluid may also damage paintwork. Check that the brake fluid level in the reservoir is near the MAX limit.
Page 453 Open and close the cover VERY CAREFULLY, as the fastener tabs are particularly fragile. Fit the cover (A) onto the right hand underwindscreen shield, inserting the rear tabs in the respective seats first and then the front tabs.
Page 454 Print Exit A3.06 Checking the power steering system fluid level Checking the power steering system fluid level FROM Ass.ly No. 98002, a different power steering fluid is prescribed. Before topping up or filling, always check which type of fluid should be used, as mixing the two different types of power steering fluid will damage the power steering system itself.
Page 455 Use the dipstick on the cap (A) to check that the power steering fluid level is between the MIN and MAX levels. There are MIN and MAX levels indicated on both sides of the dipstick. Use the levels on the side indicating the temperature 90°C.
Page 456 Print Exit A3.07 Checking coolant level and topping up Checking the cooling system fluid level CAUTION The fluid contained in the cooling system reaches extremely high temperatures and pressure. ALWAYS WORK WHEN THE ENGINE IS COLD. Check that the coolant level is always as indicated by the dotted line in the figure aside.
Page 457 02) Undo expansion tank plug (1) and slowly pour coolant, alternating this operation with repeated pauses of a few seconds so as to allow the bleeding of the air present inside system. 03) Pay attention to the passage of coolant inside vent pipe (2) from engine to expansion tank to confirm the first filling of engine cooling circuit.
Page 458 06) Check that heater circuit is off. 07) Start engine at idle speed and wait for 5 minutes. 08) Keep engine running at idle speed, check level and, if necessary, top up until MAX level. 09) Take and keep engine at 2000 rpm for 30 seconds. 10) Take and keep engine at idle speed for 30 seconds.
Page 459 Print Exit A3.08 Replacing the active carbon filter Removing the active carbon filter Replace the active carbon filter at the intervals specified in the MAINTENANCE SCHEDULE. The filter is located in front of the left hand rear wheel bay. Disconnect the battery ( F2.01).
Page 460 On pipes (2) there are two "double lock" safety clips. To disconnect the "double-lock" quick connector, using due caution and by pressing on both sides, push the safety clip out of its seat until you hear the "unclick". The difference between the safety clip "clicked" and "unclicked"...
Page 461 Tightening torque Class Fastening active carbon filter mounting bracket to Screw 8 Nm chassis Fit the active carbon filter on the relative mounting bracket as originally installed. Fit the active carbon filter (A) complete with bracket in the wheel bay. Fit the active carbon filter (A), complete with bracket, in the relative seat and tighten the two screws indicated.
Page 462 After connecting the quick connector pipes (2) correctly onto active carbon filter (A), with due caution and pressing on both sides of the "double-lock" clips indicated, push the clips into their seats until they click audibly into place and the pipes are secured correctly. The difference between the safety clip "unclicked"...
Page 463 Connect the DEIS diagnostic tester to the diagnostic socket ( F2.10). Perform the "Fuel tank tightness test" cycle.
Page 464 Print Exit A3.09 Replacing the oxygen sensors Replacing the front oxygen sensors Tightening torque Class Oxygen sensors Oxygen sensor 50 Nm Do not clean or apply grease on the oxygen sensor thread. Do not use solvents or thread locking products as they may impede correct sensor operation. The oxygen sensor thread is pre-lubricated by the manufacturer with a specific product.
Page 465 Disconnect the connector (1). Detach the indicated clamp fastening the cable. Unscrew and remove the front left hand oxygen sensor (A) from the left hand exhaust manifold and replace. Tighten the front left hand oxygen sensor (A) onto the left hand exhaust manifold. Tightening torque Class Oxygen sensor...
Page 466 Front right hand oxygen sensor Remove the engine compartment cosmetic shields ( E3.13). Remove the right hand engine compartment shield. Remove the rear wheelhouses ( E3.05). Remove the rear right hand wheelhouse. Disconnect the connector (1). Unscrew and remove the front right hand oxygen sensor (A) from the right hand exhaust manifold and replace.
Page 467 Connect the connector (1). Refit the rear wheelhouses ( E3.05). Refit the engine compartment cosmetic shields ( E3.13). Reconnect the battery ( F2.01). Replacing the rear oxygen sensors Tightening torque Class Oxygen sensors Oxygen sensor 50 Nm Do not clean or apply grease on the oxygen sensor thread. Do not use solvents or thread locking products as they may impede correct sensor operation.
Page 468 Disconnect the connector (1), detaching from the relative mounting bracket. Undo the relative fastener screw to open the clamp with sheath (2) fastening the rear left hand oxygen sensor cable. Unscrew and remove the rear left hand oxygen sensor (A) from the left hand catalytic converter and replace.
Page 469 Tighten the relative fastener screw to close the clamp with sheath (2) fastening the rear left hand oxygen sensor cable. Connect the connector (1), attaching onto the relative mounting bracket. Refit the rear wheelhouses ( E3.05). Refit the rear diffuser ( E3.12).
Page 470 Disconnect the connector (1), detaching from the relative mounting bracket. Undo the relative fastener screw to open the clamp with sheath (2) fastening the rear right hand oxygen sensor cable. Unscrew and remove the rear right hand oxygen sensor (A) from the right hand catalytic converter and replace.
Page 471 Tighten the relative fastener screw to close the clamp with sheath (2) fastening the rear right hand oxygen sensor cable. Connect the connector (1), attaching onto the relative mounting bracket. Refit the rear wheelhouses ( E3.05). Refit the rear diffuser ( E3.12).
Page 472 Print Exit A3.10 Replacing the engine air filter Replacing the air filter Place a few strips of adhesive tape to protect the bodywork on the areas shown in the photo aside. Undo the screws indicated fastening the air filter box cover (A) to the air filter box. WARNING: take care not to damage the bodywork during air filter box cover handling.
Page 473 Remove the air filter (B) from the relevant seat and replace. Fit the new air filter (B) in the relevant seat. WARNING: take care not to damage the bodywork during air filter box cover handling. Fit the air filter box cover (A) in its relevant seat. Tighten the screws indicated fastening the air filter box cover (A) to the air filter box.
Page 474 Print Exit A3.11 Replacing the air conditioning and heating system filter Replacing the pollen filter The pollen filter is located under the luggage compartment lid, on the right hand underwindscreen shield. Gently detach and remove the seal (A) from the relative seat.
Page 475 Print Exit A3.12 Checking tension and replacement of auxiliary utilities belts Checking the tension of the ancillary belt Tightening torque Class Fastening complete tensioner Screw 25 Nm Remove the rear flat undertray section ( E3.12). Crank the engine by a few revolutions then apply the frequency probe (A) of the belt tension measurement instrument (95978151) at the mid point of the lower section of belt, avoiding...
Page 476 When fitting the new belt tensioner, ensure that the locator pin (B) is correctly inserted in the relative seat on the front engine cover. Fit the tensioner (2) and fasten by tightening the screw (3). Tightening torque Class Screw 25 Nm Repeat the ancillary drive belt tension setting procedure described previously.
Page 477 Work from underneath the vehicle. With a 15 mm (1) fixed wrench applied to the tensioner pulley fastener screw (2), rotate the mobile tensioner counterclockwise to loosen the belt and enable its removal, first from the pulley on the A.C. compressor, then from the other pulleys.
Page 478: Plug (As
Print Exit A3.13 Checking and replacing spark plugs Removing the spark plugs Disconnect the battery ( F2.01). Remove the ignition coils ( F3.02). Using a universal articulated wrench, undo and remove the spark plugs (A). Refitting the spark plugs Tightening torque Class Fastening spark plug Spark plug...
Page 479 When refitting the original spark plugs, clean them with compressed air to remove any dirt. Fit the spark plugs (A) in the relevant holes in the cylinder head. Use an articulated wrench to hand tighten the spark plugs until the gasket sits up against the support seat.
Page 480 Print Exit A3.14 Checking Blow-by system pipes and connections Checking Blow-by system pipes and connections Check the state of the pipes (1), (2), (3) and the tightness of the relative clamps, around the oil tank and intake ducts. Check the connections. Replace the relative pipe and/or clamp if any leakage or sweating is noted.
Page 481 Print Exit A3.15 Checking cooling system pipes and connections Checking cooling system pipes and connections Remove the rear flat undertray section ( E3.12). Remove the central flat undertray section ( E3.12). Remove the front flat undertray section ( E3.12). Check that the pipes and pipe unions on the water pump, the radiator and the expansion tank are undamaged. Replace any worn pipe unions or loose clamps.
Page 482 Print Exit A3.16 Checking injection and ignition system pipes and connections Checking injection and ignition system pipes and connections Remove the engine compartment cosmetic shields ( E3.13). Check the state of the connection pipes between the fuel tank and the high pressure pump, and of the fuel rail on the intake manifold.
Page 483 Print Exit A3.17 Checking exhaust system connections Checking exhaust system connections Remove the rear diffuser ( E3.12). Remove the rear flat undertray section ( E3.12). Refit the rear wheelhouses ( E3.05). Remove the engine compartment cosmetic shields ( E3.13). Check the state of the system components, the connections between the manifolds and the catalytic converters, and the connections between the catalytic converters and the silencers, then check the fasteners.
Page 484 Print Exit A3.18 Checking exhaust emissions Checking exhaust emissions Remove the engine compartment cosmetic shields ( E3.13). Check CO, HC and NOx levels by connecting the tester to the unions on the connector pipes for the exhaust manifold, after removing the two nuts (1).
Page 485 Print Exit A3.19 Checking service brakes for wear Checking service brakes for wear At the intervals indicated in the Maintenance Schedule, check the state of wear of the brake pads and discs. Remove the wheels ( D2.01). Remove all. The front brake pads are fitted with a wear indicator connected to the brake failure warning light on the instrument panel.
Page 486 The front and rear CCM brake discs must always be replaced in pairs (both discs on the same axle). Front and rear CCM disc wear is calculated by the instrument panel operating software, which uses an algorithm to determine when to switch on the relative indicator to warn the driver. The bedding in procedure must be carried out after replacing discs or the pads alone.
Page 487 The figure aside shows the friction surface after an appropriate mileage or following maximum stress in track conditions; disc replacement is necessary in this case. The figure aside shows the friction surface after an appropriate mileage or following maximum stress in track conditions; disc replacement is necessary in this case.
Page 488 Regardless of the overall state of wear, discs with damage around the edge must be replaced. Unauthorised work to the holes drilled in the brake disc surface may damage the disc. If necessary, clean the holes drilled in the brake discs and the friction surface with a high pressure cleaner.
Page 489 These indices are periodically compared against a threshold value (100%). Upon reaching this threshold, an amber warning signal (possible danger of disc failure) is shown on the TFT display, warning the user that disc replacement is necessary. The user is warned of this condition by the appearance of the message: “CCM brake discs worn” on the display, together with the specific amber symbol.
Page 490 (with the estimated values from the replaced unit). 5 - Replacing the carbon discs before reaching wear threshold (“Disc Wear Index” parameter < 100%) This is a non-standard procedure and may only be performed by authorised personnel. Contact the Ferrari SAT service.
Page 491 Print Exit A3.20 Checking service/parking brake operation and control play Checking service brake/parking brake function Check the brake pedal travel and STOP light switch function. Road test the vehicle to check braking performance. Remove the rear flat undertray section ( E3.12).
Page 492 Print Exit A3.21 Checking suspension components Checking suspension components Road test the vehicle to check shock absorber performance and to check for suspension noise. Remove the wheels ( D2.01). Remove all. Check tightness of suspension components. Check that all protective gaiters are in good order and that the ball joints on the stub axle and on the rear hub holder have sufficient play.
Page 493 Print Exit A3.22 Checking vehicle set-up Checking vehicle set-up The following operations must be performed beforehand to ensure that vehicle set-up parameters are checked correctly Check that the tyre pressure is correct. Check the steering and transmission system components. Ensure that there is no backlash between the ball tie-rod of the steering box and the stub axle, and between the ball tie-rod and the rear hub holder.
Page 494 Print Exit A3.23 Checking proper installation and function of seats and seat belts Checking proper installation and function of seats and seat belts With the seat adjustment controls, check that the electrical seats move through their entire adjustment travel without impediment. Check that the seat guides are securely fastened to the floor mounts.
Page 495 Print Exit A3.24 Checking and recharging battery Checking battery charge level If you are in doubt about your battery or it if shows signs of inefficiency, check its charge level. Disconnect the battery ( F2.01). For the purposes of such a check, the battery must be at room temperature (between 15 and 25 °C) and must have been resting for at least 6 hours, i.e.
Page 496 Checking and recharging battery A Ferrari battery charger or a "stabilised" battery charger is necessary for this procedure. Disconnect the battery ( F2.01).
Page 497: Tool
Remove the battery ( F2.01). On models fitted with the special socket for the Ferrari battery charger, this socket can be used to start the vehicle when the battery is flat. If the vehicle does not have the special socket, an auxiliary battery and/or a stabilised battery charger must be connected to the terminal poles on the vehicle’s battery,...
Page 498 The maximum time necessary for the battery to start accepting a measurable charge current, in relation to voltage measured, is as follows. Charging times and procedure Voltage (Volt) Current (A) Time (hours) Standard 14.4 to 15 max. max. 6 to 12 (10 to 12 ÷...
Page 499 Battery conditioner Ferrari vehicles are equipped with a battery conditioner representing the state of the art in battery care. Using the battery conditioner contributes to prolonging battery life. The device is stored in a pocket in the car cover bag, which is located in the luggage compartment.
Page 500 A quick connector socket is installed in a protected and concealed location in the vehicle for connecting the device. The previous image shows the location of the socket for connecting the battery conditioner: under the dashboard on the passenger side. CAUTION Ensure that all lids and doors are closed correctly.
Page 501 CAUTION Ensure that all lids and doors are closed correctly. Place the battery conditioner in an easily visible location, away from heat sources and out of the reach of children. Battery conditioning may be interrupted at any time by simply disconnecting the power cable from the mains socket.
Page 502 After checking the battery conditioner connections (to the mains and to the vehicle socket) and checking for mains voltage, if lights (2) and (3) indicating the “Active” or “Passive” mode do not illuminate within a few seconds of connecting the battery conditioner, contact the Ferrari Technical Service Department to have the vehicle electrical system checked.
Page 503 conditioner. Overheating protection The battery conditioner is equipped with protection against overheating. Output power is reduced in the event of increased ambient temperature. Maintenance The battery conditioner is maintenance-free. Do not disassemble the battery conditioner. The battery conditioner casing may be cleaned with a moistened soft cloth or with neutral detergent. Always disconnect the battery conditioner from the mains before cleaning.
Page 504 Print Exit A3.25 Checking the state of the chassis and box elements Checking the state of the chassis and box elements The vehicle chassis elements, box sections and outer components are made of aluminium: all repairs and/or replacements of chassis parts or bodywork components must be performed by skilled personnel using suitable tooling and equipment.
Page 505 Print Exit A3.26 Checking wheels and tyres Checking wheels and tyres CAUTION Tyre replacement is recommend after 4 years of normal use. Frequent use in maximum load conditions and at high temperatures may lead to premature deterioration. Remove the wheels from the vehicle, then check the state of the wheel rims and tyres. Check that the tyre pressure matches the value specified Check the location and fastening of the balancer weights on the inside of the wheel rims.
Page 506 Print Exit A3.27 Inspecting the air conditioning and heating system Inspecting the air conditioning and heating system Remove the front flat undertray section ( E3.12). Remove the central flat undertray section ( E3.12). Remove the rear flat undertray section ( E3.12).
Page 507 Print Exit A3.28 Inspecting the brake system Inspecting the brake system Remove the wheels ( D2.01). Remove all. Remove the underwindscreen shields ( E4.07). Remove the right hand underwindscreen shield. Check the connection pipes leading to the callipers and to the unions on the rigid lines. Check that there is no leakage near the brake master cylinder unions or on the electrohydraulic unit.
Page 508 Print Exit A3.29 Tightening bolts, unions and clamps Tightening bolts, unions and clamps At the intervals given in the Maintenance Schedule, check the tightness of the major mechanical fittings. Refer to the tightening torque tables given at the beginning of each section. Also check that all hydraulic hose fittings and clamps are correctly tightened.
Page 509 Print Exit A3.30 Checking and lubricating hinges and adjusters Checking and lubricating hinges and adjusters Check that the door hinges and the engine and luggage compartment lid hinges are correctly fastened and that they open and close without free play or noise. Check that the door locks and the engine and luggage compartment lid release mechanisms function correctly.
Page 510 Treating interior trim in leather - Alcantara Treating interior leather upholstery Proper and regular treatment (at least once a year) will preserve the natural qualities and softness of Ferrari leather trim. For this precise purpose, a range of specific leather care products (Cleaner and Cream), developed and tested by Ferrari, is also available.
Page 511 Weekly cleaning Avoid the use of rags/blotting paper because they could leave ink on the material. After dusting Alcantara®, wipe with a slightly moistened white cotton cloth. Yearly cleaning With removable upholstery, machine wash using the following procedure (general guidelines for washing). With non-removable upholstery, use specific products for cleaning Alcantara®.
Page 512 In case of dry-cleaning do not use trichloroethylene and avoid direct contact with equipment that uses steam. Alcantara® must not be treated with chlorine-based bleaches. Never use a centrifuge. With removable upholstery, Alcantara® may be safely machine washed at approximately 30°C, using a neutral detergent.
Page 513 Water-soluble stains Preferably use specific products for cleaning Alcantara®. If no specific products are available, use water, lemon juice or pure ethyl alcohol (spirits), depending on the case. Fruit juice, jam, jelly, ketchup: use lukewarm water; rinse by patting with clean water. Blood, egg: use cold water;...
Page 514 Print Exit A3.32 Checking radiators for fouling Checking radiators for fouling Detritus from the road may enter the vehicle front air intake and foul the radiators; over time, this may compromise the functionality of the cooling systems so that they are no longer capable of providing sufficient cooling.
Page 515 To remove grease stains, use a clean Yellow 3M microfibre cloth (Ferrari p/n 571.400.022) moistened in R107/S solvent (heptane). Use a new cloth only, or a cloth that has never been used with demineralised water or Glass cleaning solution.
Page 516 Print Exit A3.34 Service counter reset Service counter reset Connect the DEIS tester to the diagnostic socket. Switch on the DEIS tester. Click the DEIS button. Select "NQS - Instrument panel". Click "Diagnostics" Select "SET SERVICE"...
Page 517 Technical specifications Page 1 of 1 Print Exit B1.01 Technical specifications Engine specifications The engine is a naturally aspirated V8 with a 180° crank. variable valve timing with continuous high pressure timing adjuster mechanism on all camshafts; timing chains (one per cylinder bank) with hydraulic chain tensioners; four overhead composite camshafts (two per cylinder bank) and four valves per cylinder with self-adjusting hydraulic tappets;...
Page 518 Specific tooling and equipment Page 1 of 5 Print Exit B1.02 Specific tooling and equipment Tensiometer (95978151) Seem DIAPAZ. Hook 95973432 (AV 3432) for hoisting engine.
Page 519 Specific tooling and equipment Page 2 of 5 Hook (AV 3979) for hoisting engine. Torque wrench 95978172 (AV 8172) (Replaces torque wrench USAG 815F) Wrench 95978175 (AV 8175) tightening fuel pump filter retainer ring.
Page 520 Specific tooling and equipment Page 3 of 5 Wrench 95978176 (AV 8176) tightening fuel level sensor. Tailpipe cowl for exhaust fume extraction 95978250 (AV 8250) for use exclusively together with one of the extension elements AV 8177 for connection to an exhaust gas extraction system.
Page 521 Specific tooling and equipment Page 4 of 5 Pins for lifting engine-gearbox assembly 95978253 (AV 8253) for lifting engine/gearbox assembly off rear subframe after removal of subframe from vehicle. Engine retainer bracket for gearbox removal 95978254 (AV 8254) removing the gearbox. Template 95978257 (AV 8257) fitting flexible exhaust pipe.
Page 522 Specific tooling and equipment Page 5 of 5 Hook 95977564 (AS 107564) for lifting the gearbox.
Page 523 Tightening torques Page 1 of 2 Print Exit B1.03 Tightening torques Tightening torque Class Fastening complete tensioner Screw 25 Nm Fastening spark plug Spark plug 11 Nm Fastening engine mounting bush - chassis Screw 50 Nm Fastening engine strut - engine mounting bush Screw 15 Nm Screw...
Page 524 Tightening torques Page 2 of 2 Tightening torque Class Fastening engine oil tank to gearbox Screw 10 Nm Fastening engine oil recovery and pick-up pipe Screw 10 Nm Fastening oil pump bush retainer bracket Screw 10 Nm Fastening oil-water heat exchanger Screw 10 Nm Fastening solenoid valve mounting bracket to...
Page 525 Removing the complete engine Page 1 of 26 Print Exit B2.01 Removing the complete engine Removing the complete engine CAUTION For safety reasons, the VEHICLE MAY ONLY BE LIFTED WITH THE ANTI-TIPPING SAFETY RETAINERS INSTALLED. Disconnect the battery ( F2.01). Remove the engine compartment lid ( E3.01).
Page 526 Removing the complete engine Page 2 of 26 Disconnect the pipe (46) leading from the secondary air pump, removing the indicated clamp. Open the indicated clamps and remove the secondary air pipe (2), complete with valves, from the engine compartment. Remove the cover (92).
Page 527 Removing the complete engine Page 3 of 26 FROM Ass.ly No. 90802 Open the indicated clamp on the low pressure pipe (3). Remove the cover (91). Disconnect the low pressure pipe (5) from the fuel pump filter. Disconnect the pipe (4) from the left hand fuel tank. A "double-lock"...
Page 528 Removing the complete engine Page 4 of 26 FROM Ass.ly No. 90802 Open the indicated clamp on the low pressure pipe (5). Remove the right hand front heat shield (48), undoing the indicated screws. Remove the right hand rear heat shield (47), undoing the screws indicated by the red arrows.
Page 529 Removing the complete engine Page 5 of 26 UP TO Ass.ly No. 90801 Undo the screw indicated and remove the power steering pump shield (6). UP TO Ass.ly No. 90801 Undo the union (7) on the power steering pump. Place a container under the clamp (14). Loosen the clamp (14) and disconnect the pipe (15) leading from the expansion tank.
Page 530 Removing the complete engine Page 6 of 26 UP TO Ass.ly No. 90801 Remove the clamp (20) on the pipe retainer pillory block, undoing the screws indicated. UP TO Ass.ly No. 90801 Disconnect the power steering system pipe (8), removing the indicated clamp. Disconnect the quick connector (9) of the brake servo vacuum pipe (19).
Page 531 Removing the complete engine Page 7 of 26 UP TO Ass.ly No. 90801 Loosen the clamp (16) and disconnect the pipe (17) from the front timing cover. FROM Ass.ly No. 90802 Remove the indicated clamp and disconnect the power steering system pipe (8). Disconnect the quick connector (7) on the power steering system pipe.
Page 532 Removing the complete engine Page 8 of 26 FROM Ass.ly No. 90802 Disconnect the quick connector (9) of the brake servo vacuum pipe. Place a container under the clamp (10). Loosen the clamp (10) and disconnect the pipe (11) from the front timing cover. Pour the fluid drained from the system into a container and seal it.
Page 533 Removing the complete engine Page 9 of 26 Disconnect the evaporative emissions control system solenoid valve pipe (18) from the left hand plenum, removing the indicated clamp. Lift the cover (21) of the junction box and undo the indicated nut fastening the cable (45). Detach the clamps retaining the cable (45) to the chassis.
Page 534 Removing the complete engine Page 10 of 26 Release the right hand injection cable (23), cutting the indicated cable ties and detaching the indicated clamps fastened to the chassis. Disconnect the connector (24) from the right hand Motronic ECU, and disconnect the connector (25) from the engine compartment cable junction.
Page 535 Removing the complete engine Page 11 of 26 Pull out the right hand injection cable (22) and place on top of the intake manifold. Release the left hand injection cable (28), removing the indicated clamps. Disconnect the front left hand oxygen sensor connector (29) and remove the indicated clip.
Page 536 Removing the complete engine Page 12 of 26 Disconnect the connector (32) from the left hand Motronic ECU. Pull out the left hand injection cable (28) and place on top of the intake manifold. Remove the right hand removable subframe (33) from the chassis, undoing the screws indicated.
Page 537 Removing the complete engine Page 13 of 26 Remove the U-bracket (35), undoing the two screws indicated. Undo the two screws indicated fastening the heat shield (36). Undo the fours screws indicated fastening the left hand removable subframe (34) to the chassis. Remove the indicated clamp fastening the secondary air pipe (46) and retrieve the pipe.
Page 538 Removing the complete engine Page 14 of 26 Remove the heat shields (37) from above the engine mounting bushes on both sides, undoing the screws indicated. Fit the bracket 8252)onto the stud bolts of cylinder No. 7 on the left hand cylinder bank. Fit the bracket 8252)onto the stud bolts of cylinder No.
Page 539 Removing the complete engine Page 15 of 26 Tighten the three shims, elements 01 of the tool 8252), onto the stud bolts of the crankcase. Fit the hook 3432) onto the stud bolts of the shims installed previously, and fasten by tightening the three nuts indicated.
Page 540 Removing the complete engine Page 16 of 26 Using a mobile hydraulic hoist with a minimum load capacity of 300 Kg, position the lift hook over the engine. Use a suitable strap (39) to fasten the hook 3979) to the hoist. Using two suitably sized straps (41) and carabiners, connect the hook 3979) to the brackets...
Page 541 Removing the complete engine Page 17 of 26 When removing the engine, work with due CAUTION to prevent any of the engine's components - and the engine oil pump, the variable timing adjuster control solenoid valves and the mounting brackets for the secondary air pipes mounted on the cylinder heads in particular - from colliding with the chassis.
Page 542 Removing the complete engine Page 18 of 26 Remove the heat shield (2), undoing the screw indicated. FROM Ass.ly No. 92290 Remove the heat shield (2), undoing the screw indicated. Clean the area surrounding the fastener point for the clutch hydraulic system oil pipes thoroughly using a suitable degreaser that does not leave residue.
Page 543 Removing the complete engine Page 19 of 26 Undo the screws indicated fastening the retainers on the pillory blocks holding the clutch hydraulic system oil pipes (4) and the gear oil pipes (6). Clean the area surrounding the gear oil pipe fastener point thoroughly with a suitable degreaser that does not leave residue.
Page 544 Removing the complete engine Page 20 of 26 Remove the indicated clamps fastening the pipes to the rear subframe. Undo the screw indicated fastening the ground cable (38) onto the engine and release the cable from the indicated fastener clamp on the starter motor shield.
Page 545 Removing the complete engine Page 21 of 26 FROM Ass.ly No. 96750 (see Spare Parts Catalogue to see vehicles not affected by modification) Release the drain pipe (23) from the rubber lined bracket by undoing the indicated screw. Release the drain pipe (23) from the rubber lined brackets by undoing the indicated screws.
Page 546 Removing the complete engine Page 22 of 26 FROM Ass.ly No. 96750 (see Spare Parts Catalogue to see vehicles not affected by modification) Unscrew the indicated screws fastening the lower gearbox mounting cross-member (9). Unscrew the indicated screws and remove the lower gearbox mounting cross-member (9).
Page 547 Removing the complete engine Page 23 of 26 Remove the right hand front heat shield (11), undoing the indicated screws. Remove the right hand rear heat shield (12), undoing the screws indicated by the red arrows. Follow the same procedure to remove the front and rear heat shields on the left-hand side of the engine.
Page 548 Removing the complete engine Page 24 of 26 Screw the hoisting pins 8253) into the vertical holes in the engine-gearbox connector tie-rods (14). FROM Ass.ly No. 92290 Remove the two eyebolts (19) from the tool 107564). FROM Ass.ly No. 92290 Screw the two eyebolts (19), removed previously from the tool, into the relative holes on the gearbox.
Page 549 Removing the complete engine Page 25 of 26 The engine-gearbox assembly must be lifted from the rear subframe: this operation requires the use of a mobile hydraulic hoist or a bridge crane with a minimum load capacity of 300 Kg, element 31 of the hoisting hook 3432) (which is also used for the Enzo) and the...
Page 550 Removing the complete engine Page 26 of 26 On both sides, undo the screws (42) fastening the engine strut to the engine mounting bush, retrieving the relative washer. Undo the nut (21) retrieving the washer. Remove the pin (22) fastening the bushing mounting (15) to the rear subframe, retrieving the washer.
Page 551 Refitting the complete engine Page 1 of 30 Print Exit B2.02 Refitting the complete engine Refitting the complete engine Tightening torque Class Fastening engine strut - engine mounting bush Screw 15 Nm Screw 103 Nm Fastening engine mounting bush - chassis Screw 50 Nm Fastening heat shield - engine mounting bush...
Page 552 Refitting the complete engine Page 2 of 30 Fit the bracket 8252)onto the stud bolts of cylinder No. 7 on the left hand cylinder bank. Fit the bracket 8252)onto the stud bolts of cylinder No. 2 on the right hand cylinder bank. Tighten the three shims, elements 01 of the tool 8252), onto the stud bolts of the crankcase.
Page 553 Refitting the complete engine Page 3 of 30 Using a mobile hydraulic hoist with a minimum load capacity of 300 Kg, position the lift hook over the engine. Use a suitable strap (39) to fasten the hook 3979) to the hoist. Using two suitably sized straps (41) and carabiners, connect the hook 3979) to the brackets...
Page 554 Refitting the complete engine Page 4 of 30 Fit the engine on the engine mounting bushes, aligning the bushes correctly. On both sides, fit and pretighten the screws (42) fastening the engine strut to the engine mounting bush after installing the relevant washer. Tightening torque Class Screw...
Page 555 Refitting the complete engine Page 5 of 30 Working underneath the vehicle, install the tool 8254) onto the chassis, tightening the two screws indicated, to support the weight of the engine and prevent it from tipping. Remove the block (F) fitted previously. Use a feeler gauge to check that the gap between the retainer bracket (44) and the engine mounting bush (43), along the "X"...
Page 556 Refitting the complete engine Page 6 of 30 Fit and fasten the heat shields (37) over the engine mounting bushes on both sides, tightening the screws indicated. Tightening torque Class Screw 9 Nm Tighten the screw indicated on the ground cable (38) onto the engine and secure the cable to the indicated fastener clamp on the starter motor shield.
Page 557 Refitting the complete engine Page 7 of 30 Tighten the fours screws indicated fastening the left hand removable subframe (34) to the chassis. Tightening torque Class Screw 24 Nm Tighten the two screws indicated fastening the heat shield (36). Tightening torque Class Screw 9 Nm...
Page 558 Refitting the complete engine Page 8 of 30 Lay out the left hand injection cable as originally fitted on the chassis. Connect the connector (32) to the left hand Motronic ECU. Fasten the left hand injection cable (28), fitting the indicated clamps, and connect the connector (31) to the engine compartment cable junction.
Page 559 Refitting the complete engine Page 9 of 30 Lay out the right hand injection cable as originally fitted on the chassis. Connect the front right hand oxygen sensor connector (27) and fit the indicated clip. Connect the connectors (26) to the ELDOR ECU. Fasten the right hand injection cable (22) leading to the ELDOR ECU, fitting the indicated clamps.
Page 560 Refitting the complete engine Page 10 of 30 Fasten the right hand injection cable (23), fitting the indicated clamps. Lift the cover (21) of the junction box and tighten the indicated nut fastening the cable (45). Tightening torque Class 15 Nm Fit the cable retainer clamps (45) as originally installed on the chassis.
Page 561 Refitting the complete engine Page 11 of 30 UP TO Ass.ly No. 90801 Connect the pipe (17) to the front timing cover and fasten by tightening the clamp (16). UP TO Ass.ly No. 90801 Fasten the brake servo vacuum pipe (19) in the relative seat on the pillory block.
Page 562 Refitting the complete engine Page 12 of 30 Connect the pipe (15) leading from the expansion tank and fasten by tightening the clamp (14). UP TO Ass.ly No. 90801 Tighten the union (7) on the power steering pump Tightening torque Class Union 37 Nm...
Page 563 Refitting the complete engine Page 13 of 30 FROM Ass.ly No. 90802 Connect the pipe (13) to the pressure switch/thermostat and fasten by tightening the clamp (12). Connect the pipe (11) to the front timing cover and fasten by tightening the clamp (10). Connect the quick connector (9) of the brake servo vacuum pipe.
Page 564 Refitting the complete engine Page 14 of 30 FROM Ass.ly No. 91654 Connect the pipe (93) to the rigid pipe. Fit and tighten a new clamp as indicated by the red arrow. Secure the pipe (93) by fastening to the clamp indicated by the black arrow.
Page 565 Refitting the complete engine Page 15 of 30 Connect the low pressure pipe (5) to the fuel pump filter. After connecting the quick connector pipe (4) correctly to the left hand fuel tank, with due caution and pressing on both sides of the "double-lock"...
Page 566 Refitting the complete engine Page 16 of 30 Connect the low pressure pipe (3) to the fuel pump filter. Fasten the pipes (4) to the engine with the indicated clamp. After connecting the quick connector pipes (4) correctly to the right hand fuel tank, with due caution and pressing on both sides of the "double-lock"...
Page 567 Refitting the complete engine Page 17 of 30 Connect the pipe (46) leading from the secondary air pump to the relative pipe (2), fitting the indicated clamp. Close the indicated clamps fastening the secondary air pipe (2), complete with valves. Connect the pneumatic actuator system pipes (1) and fasten with a new clamp as indicated.
Page 568 Refitting the complete engine Page 18 of 30 Tightening torque Class Fastening engine strut - engine mounting bush Screw 15 Nm Screw 103 Nm Fastening engine mounting bush - chassis Screw 50 Nm Fastening gearbox mounting bushing to rear 50 Nm subframe 100 Nm Fastening heat shield - engine mounting bush...
Page 569 Refitting the complete engine Page 19 of 30 Screw the hoisting pins 8253) into the vertical holes in the engine-gearbox connector tie-rods (14). FROM Ass.ly No. 92290 Remove the two eyebolts (19) from the tool 107564). FROM Ass.ly No. 92290 Screw the two eyebolts (19), removed previously from the tool, into the relative holes on the gearbox.
Page 570 Refitting the complete engine Page 20 of 30 The engine-gearbox assembly must be lifted and positioned in its relevant seat on the rear subframe: this operation requires the use of a mobile hydraulic hoist or a bridge crane with a minimum load capacity of 300 Kg, element 31 of the hoisting hook 3432) (which is also used...
Page 571 Refitting the complete engine Page 21 of 30 Lift the engine-gearbox assembly by a few millimetres, ensuring that the bar tension is uniform and that the assembly itself lifts evenly. Lift the engine-gearbox assembly and set down in the relevant seats on the rear subframe, taking care to avoid collisions with any other components.
Page 572 Refitting the complete engine Page 22 of 30 Lower the engine-gearbox assembly, locating the engine struts on the bushings. On both sides, hand-tighten the screws (42) fastening the engine strut to the engine mounting bush, after installing the relevant washer. On both sides pretighten the screws (42) fastening the engine strut to the engine mounting bushing.
Page 573 Refitting the complete engine Page 23 of 30 Pretighten the nut (21). Tightening torque Class 50 Nm Tighten the nut (21). Tightening torque Class 100 Nm Remove all the hoisting tools fitted previously. Use a feeler gauge to check that the gap between the retainer bracket (44) and the engine mounting bush (43), along the "X"...
Page 574 Refitting the complete engine Page 24 of 30 Fit the right hand rear heat shield (12) in the relevant seat and fasten by tightening the screws indicated by red arrows. Fit the right hand front heat shield (11) in the relevant seat and fasten by tightening the indicated screws.
Page 575 Refitting the complete engine Page 25 of 30 Apply AREXONS SYSTEM 52A43 - MEDIUM STRENGTH THREAD LOCK on the thread of the screws indicated. Hand-tighten the indicated screws fastening the lower gearbox mounting cross-member (9). FROM Ass.ly No. 96750 (see Spare Parts Catalogue to see vehicles not affected by modification) Apply AREXONS SYSTEM 52A43 - MEDIUM STRENGTH THREAD LOCK on the thread of...
Page 576 Refitting the complete engine Page 26 of 30 FROM Ass.ly No. 96750 (see Spare Parts Catalogue to see vehicles not affected by modification) Tighten the indicated screws fastening the lower gearbox mounting cross member (9), following the sequence shown in the photo. Tightening torque Class Screw...
Page 577 Refitting the complete engine Page 27 of 30 FROM Ass.ly No. 96750 (see Spare Parts Catalogue to see vehicles not affected by modification) Fasten the drain pipe (23) inside the rubber lined bracket tightening the indicated screw. Tighten the screw indicated on the ground cable (38) onto the engine and secure the cable to the indicated fastener clamp on the starter motor shield.
Page 578 Refitting the complete engine Page 28 of 30 Connect the pneumatic actuator system pipes (10) and fasten by tightening the indicated clamp. Fasten the gearbox wiring harness to the chassis, fitting the clamp and tightening the screw indicated, then connect the three connectors (8). Fit the mounting bracket (7) on the gearbox stud bolts and fasten the oil pipes of both systems onto the relevant pillory blocks.
Page 579 Refitting the complete engine Page 29 of 30 Clean the area surrounding the fastener point for the clutch hydraulic system oil pipes thoroughly using a suitable degreaser that does not leave residue. Remove the plugs fitted previously on the oil pipes. Replace the O-rings on the clutch hydraulic system oil pipes (4) and fit into the relevant seats.
Page 580 Refitting the complete engine Page 30 of 30 Tighten the screws indicated fastening the heat shield (2). Fit and fasten the shield (1), tightening the 2 nuts and 2 screws indicated. Refit the axle shaft ( C4.01). Refit both. Refit the silencers ( B7.04).
Page 581 Engine overhaul - Disassembly Page 1 of 6 Print Exit B2.03 Engine overhaul - Disassembly Removing the cylinder head covers Remove the complete engine ( B2.01). Remove the ignition coils ( F3.02). Right hand cover Disconnect the connectors (1). Release the clip (2).
Page 582 Engine overhaul - Disassembly Page 2 of 6 Disconnect the ground cable (3) by undoing the indicated screw. Disconnect the connector (4). Detach the pipe (5) by loosening the indicated clamp. Disconnect the connector (6). Open the clip (7) and release the relative pipes. DAL Ass.ly No.
Page 583 Engine overhaul - Disassembly Page 3 of 6 Undo the screws indicated. Remove the cover (A). Undo the screws indicated. Remove the cover carefully. Left hand cover Disconnect the connectors (1).
Page 584 Engine overhaul - Disassembly Page 4 of 6 Release the clip (2). Disconnect the ground cable (3) by undoing the indicated screw. Disconnect the connector (4). Detach the pipe (5) by loosening the indicated clamp. Disconnect the connector (6).
Page 585 Engine overhaul - Disassembly Page 5 of 6 Open the clip (7) and release the relative pipes. Open the clip (8) and release the relative pipes. Undo the screws indicated. Remove the cover (A). Undo the screws indicated. Remove the cover carefully. Removing the front timing cover (with engine in vehicle)
Page 586 Engine overhaul - Disassembly Page 6 of 6 In preparation...
Page 587 Engine overhaul - Inspections Page 1 of 1 Print Exit B2.04 Engine overhaul - Inspections In preparation In preparation...
Page 588 Engine overhaul - Rebuild Page 1 of 7 Print Exit B2.05 Engine overhaul - Rebuild Refitting the front timing cover (with engine in vehicle) In preparation Refitting the cylinder head covers Tightening torque Class Fastening the cylinder heads Screw (pretightening) 5 Nm Screw 11 Nm...
Page 589 Engine overhaul - Rebuild Page 2 of 7 Replace the gasket (9). Replace the gaskets (10). Lubricate the gaskets (11) with soapy water. Fit the cover carefully, tacking the indicated screws. Pretighten the indicated screws in the sequence given. Tightening torque Class Screw (pretightening) 5 Nm...
Page 590 Engine overhaul - Rebuild Page 3 of 7 FROM Ass.ly No. 91654, position the respective pipe correctly and close the clip (8). Position the respective pipes correctly and close the clip (7). Connect the connector (6). Connect the pipe (5), tightening the indicated clamp. Connect the connector (4).
Page 591 Engine overhaul - Rebuild Page 4 of 7 Attach the clip (2). Connect the connectors (1). Left hand cover Clean the cover mating surface thoroughly. Apply a suitable quantity of paste CAF 4 in the indicated positions.
Page 592 Engine overhaul - Rebuild Page 5 of 7 Replace the gasket (9). Replace the gaskets (10). Lubricate the gaskets (11) with soapy water. Fit the cover carefully, tacking the indicated screws. Pretighten the indicated screws in the sequence given. Tightening torque Class Screw (pretightening) 5 Nm...
Page 593 Engine overhaul - Rebuild Page 6 of 7 Position the respective pipes correctly and close the clip (8). Position the respective pipes correctly and close the clip (7). Connect the connector (6). Connect the pipe (5), tightening the indicated clamp. Connect the connector (4).
Page 594 Engine overhaul - Rebuild Page 7 of 7 Attach the clip (2). Connect the connectors (1). Refit the ignition coils ( F3.02). Refit the complete engine ( B2.02).
Page 595 Engine fuel system layout Page 1 of 1 Print Exit B3.01 Engine fuel system layout Fuel system layout A - Fuel tanks B - Fuel pumps C - High pressure pumps D - Fuel rail E - Low pressure pipes F - High pressure pipes G - Fuel level sensor H - Fuel pump filters...
Page 596 Fuel tank Page 1 of 12 Print Exit B3.02 Fuel tank Removing left hand fuel tank Disconnect the battery ( F2.01). Drain the fuel system ( B3.06). Remove the rear subframe ( E2.02). Remove the secondary air pump ( F3.12). Remove the passenger compartment trim panels ( E4.04).
Page 597 Fuel tank Page 2 of 12 Disconnect the connector (4). Undo the screw indicated by the red arrow on the ground cable (5). Disconnect the pipe (6). A "double-lock" safety clip is fitted on the union. To disconnect the "double-lock" quick connector, using due caution and by pressing on both sides, push the safety clip out of its seat until you hear the "unclick".
Page 598 Fuel tank Page 3 of 12 Hold properly the left hand fuel tank (A). Undo the nuts indicated. UP TO Ass.ly No. 89228, retrieve the shims (9). Remove the belts (10) from the relative seats. Remove the left hand fuel tank (A). Refitting left hand fuel tank Tightening torque Class...
Page 599 Fuel tank Page 4 of 12 Check the state of the pads; replace if necessary. Apply a layer of grease TUTELA MR3 on the pads, if necessary. Fit the left hand fuel tank (A). Hold properly the left hand fuel tank (A). Lay out the straps (10) in the relative guides on the left hand fuel tank (A).
Page 600 Fuel tank Page 5 of 12 Fit the upper heat shield (8). Hand tighten the screws indicated. Tightening torque Class Screw 9 Nm Fit the lower heat shield (7). Tighten the indicated fasteners. Tightening torque Class Screw 9 Nm 5 Nm After connecting the quick connector pipe (6) correctly to the fuel tank, with due caution and pressing on both sides of the "double-lock"...
Page 601 Fuel tank Page 6 of 12 In the passenger compartment, connect the connector (3). Fasten the cap (2) in the relative housing. Fasten the cable grommet (1) on the cap (2). Refit the passenger compartment trim panels ( E4.04). Refit the secondary air pump ( F3.12).
Page 602 Fuel tank Page 7 of 12 Disconnect the connector (4). Undo the screw indicated by the red arrow on the ground cable (5). Disconnect the pipes (6). There are two "double-lock" safety clips fitted onto the unions. To disconnect the "double-lock" quick connector, using due caution and by pressing on both sides, push the safety clip out of its seat until you hear the "unclick".
Page 603 Fuel tank Page 8 of 12 Undo the screws indicated. Remove the upper heat shield (7). Disconnect the pipe (8). A "double-lock" safety clip is fitted on the union. To disconnect the "double-lock" quick connector, using due caution and by pressing on both sides, push the safety clip out of its seat until you hear the "unclick".
Page 604 Fuel tank Page 9 of 12 Remove the belts (11) from the relative seats. Remove the right hand fuel tank (A). Refitting the right hand fuel tank Tightening torque Class Fastening fuel tank retainer belts 20 Nm Fastening heat shield Screw 9 Nm 5 Nm...
Page 605 Fuel tank Page 10 of 12 Fit the right hand fuel tank (A). Support the weight of the right hand fuel tank (A) adequately. Lay out the straps (11) in the relative guides on the right hand fuel tank (A). UP TO Ass.ly No.
Page 606 Fuel tank Page 11 of 12 Fit the upper heat shield (7). Hand tighten the screws indicated. Tightening torque Class Screw 9 Nm Fit the lower heat shield (2). Tighten the indicated fasteners. Tightening torque Class Screw 9 Nm 5 Nm Fit the pipes (1) on the heat shields.
Page 607 Fuel tank Page 12 of 12 After connecting the quick connector pipes (6) correctly to the fuel tank, with due caution and pressing on both sides of the "double-lock" clips indicated, push the clips into their seats until they click audibly into place and the pipes are secured correctly.
Page 608 Fuel pump assembly Page 1 of 9 Print Exit Copyright Ferrari S.p.A. - P.IVA 00159560366 B3.03 Fuel pump assembly Removing the fuel pump filter CAUTION FUEL IS HIGHLY FLAMMABLE. NEVER WORK ON A HOT ENGINE. TO PREVENT FIRE RISKS AND FUEL LEAKAGE, WORK ONLY ON A COLD ENGINE WITH AN EMPTY FUEL TANK.
Page 609 Fuel pump assembly Page 2 of 9 Remove the cover (1). Disconnect the connector (3). Remove the ground cable (4), undoing the indicated screw and retrieving the lock washer. CAUTION When connecting a fuel system pipe, bear in mind that the line may be pressurised. Proceed therefore with caution and keep away any type of flame as there is a risk of fuel spraying onto the operator.
Page 610 Fuel pump assembly Page 3 of 9 Fit the tool 8175) in the relative seat on the fuel pump filter ring nut (6). Turn the fuel pump filter ring nut (6) counterclockwise to bring the lock pin (shown in the box in the photo) into the position indicated. Remove the tool and remove the fuel pump filter ring nut (6).
Page 611 Fuel pump assembly Page 4 of 9 for the right hand fuel pump are given. Before refitting, thoroughly clean all the parts removed and dry with compressed air. ALWAYS REPLACE the ring nut and relative O- ring whenever the fuel pump is removed. ALWAYS replace the O-ring (11).
Page 612 Fuel pump assembly Page 5 of 9 To ensure that the filter is installed correctly, the tab on the fuel pump filter (A) must match up with the respective seat on the fuel tank, as shown in the photo aside. ALWAYS REPLACE the ring nut and relative O- ring whenever the fuel pump is removed.
Page 613 Fuel pump assembly Page 6 of 9 Connect the fuel pipe (5) onto the fuel pump filter. Fasten the ground cable (4), fitting the lock washer and tightening the indicated screw. Connect the connector (3). FROM Ass.ly No. 90802, fasten the clip indicated by the red arrow.
Page 614 Fuel pump assembly Page 7 of 9 Perform the "Fuel tank tightness test" cycle. Replacing the fuel pump CAUTION FUEL IS HIGHLY FLAMMABLE. NEVER WORK ON A HOT ENGINE. TO PREVENT FIRE RISKS AND FUEL LEAKAGE, WORK ONLY ON A COLD ENGINE WITH AN EMPTY FUEL TANK.
Page 615 Fuel pump assembly Page 8 of 9 Open the indicated clamp. Remove the fuel pump (A) from the fuel tank floor. Remove the fuel pump (A) from the tank and replace. In the case of the left hand fuel pump, take care not to bend the fuel level sensor rod.
Page 616 Fuel pump assembly Page 9 of 9 Fasten the fuel pump pipes (A) by closing the indicated clamp. Refit the fuel pump filter ( B3.03). Reconnect the battery ( F2.01). Connect the DEIS diagnostic tester to the diagnostic socket ( F2.10).
Page 617 Fuel level sensor Page 1 of 4 Print Exit B3.04 Fuel level sensor Replacing the fuel level sensor CAUTION FUEL IS HIGHLY FLAMMABLE. NEVER WORK ON A HOT ENGINE. TO PREVENT FIRE RISKS AND FUEL LEAKAGE, WORK ONLY ON A COLD ENGINE WITH AN EMPTY FUEL TANK.
Page 618 Fuel level sensor Page 2 of 4 Disconnect the connector (3) and, using a suitable tool, prise off and remove the safety clip (4) from the fuel level sensor (A). Fit the tool 8176) in the relative seat on the fuel level sensor (A).
Page 619 Fuel level sensor Page 3 of 4 Fit the tool 8176) in the relative seat on the fuel level sensor (A). Turn the fuel level sensor (A) clockwise to bring the retainer clips (shown in the box in the photo) into the position indicated.
Page 620 Fuel level sensor Page 4 of 4 Perform the "Fuel tank tightness test" cycle.
Page 621 Fuel vapour separator Page 1 of 3 Print Exit B3.05 Fuel vapour separator Removing the fuel vapour separator Remove the engine compartment cosmetic shields ( E3.13). Release pipes (1) opening the indicated clamps, and disconnect them from right hand fuel tank (2).
Page 622 Fuel vapour separator Page 2 of 3 FROM Ass.ly No. 93334 Open the indicated studs. Open the shielding (B). Remove the indicated clamps fastening the pipe (7) and disconnect the pipe from the active carbon filter. A "double-lock" safety clip (8) is fitted on the union. To disconnect the "double-lock"...
Page 623 Fuel vapour separator Page 3 of 3 FROM Ass.ly No. 93334 Close the shielding (B). Fasten the indicated studs. After connecting the quick connector pipes (1) and (3) of fuel vapours separator (A) correctly to left hand fuel tank (4), with due caution and pressing on both sides of the "double-lock"...
Page 624 Draining the engine fuel system Page 1 of 1 Print Exit B3.06 Draining the engine fuel system Draining the fuel system CAUTION Fuel is highly flammable. NEVER WORK ON A HOT ENGINE. This procedure requires the use of an aspirator pump compliant with EEC standards. Connect a suitable pipe at least 2.5 metres in length, with a maximum diameter of 10 mm, to the aspirator pump.
Page 625 Air intake system layout Page 1 of 1 Print Exit B4.01 Air intake system layout A - Air ducts B - Air filter box C - Air flow meters D - Throttle bodies E - Intake manifold...
Page 626 Air ducts Page 1 of 2 Print Exit B4.02 Air ducts Removing the engine air ducts The following procedure is for removing the left hand duct. The procedure for removing the right hand duct is identical. Remove the engine compartment cosmetic shields ( E3.13).
Page 627 Air ducts Page 2 of 2 Refitting the engine air ducts Tightening torque Class Fastening engine air ducts Screw 6 Nm Fastening hose unions to engine air ducts Screw collar 4 Nm The following procedure is for refitting the left hand duct. The procedure for refitting the right hand duct is identical.
Page 628 Air filter box Page 1 of 6 Print Exit B4.03 Air filter box Replacing the air filter Place a few strips of adhesive tape to protect the bodywork on the areas shown in the photo aside. Undo the screws indicated fastening the air filter box cover (A) to the air filter box.
Page 629 Air filter box Page 2 of 6 Remove the air filter (B) from the relevant seat and replace. Fit the new air filter (B) in the relevant seat. WARNING: take care not to damage the bodywork during air filter box cover handling. Fit the air filter box cover (A) in its relevant seat.
Page 630 Air filter box Page 3 of 6 Undo the indicated nuts fastening the air flow meters (A) to the air filter box cover (B). Undo the screws indicated fastening the air filter box cover (B). Remove the air filter box cover (B) from the relative seat, disconnecting from the air flow meters (A) and retrieving the O-rings.
Page 631 Air filter box Page 4 of 6 Undo the indicated screws fastening the bracket (F) to the back of the air filter box (D). Remove the bracket (F) from the relevant seat. Working with due caution, remove the air filter box from the relevant seat. Refitting the engine air filter box Tightening torque Class...
Page 632 Air filter box Page 5 of 6 Fit the right hand bracket (E) in the relative seat. Tighten the indicated screws fastening the right hand bracket (E) to the engine compartment lid mounting. Tighten the nuts (1) fastening the air filter box (D). Tightening torque Class 9 Nm...
Page 633 Air filter box Page 6 of 6 Fit the air filter box cover (B) in the relative seat, refitting the O-rings and connecting the cover to the air flow meters (A). Tighten the screws indicated fastening the air filter box cover (B). Tighten the indicated nuts fastening the air flow meters (A) to the air filter box cover (B).
Page 634 Air intake manifold Page 1 of 18 Print Exit B4.04 Air intake manifold Removing the intake manifold Disconnect the battery ( F2.01). Remove the indicated clamp and disconnect the respective pneumatic actuator system pipes (2). Remove the clamps (1) and detach the motorised throttle bodies from the plenums.
Page 635 Air intake manifold Page 2 of 18 Right-hand side Disconnect the pipe (6) from the rigid pipe, removing the indicated clamp. Remove the vacuum pipe (7) from the plenum, undoing the indicated screw. FROM Ass.ly No. 91654 _ Right hand side Remove the clamp indicated.
Page 636 Air intake manifold Page 3 of 18 Right-hand side Disconnect the pipes (4) and (5) from the plenum, removing the indicated clamps. Right-hand side Detach the connector (8) from the mounting bracket. Right-hand side Remove the wiring harness retainer bracket (9), undoing the indicated screws.
Page 637 Air intake manifold Page 4 of 18 Right-hand side Remove the wiring harness retainer brackets (10) and (11), undoing the indicated screws. Right-hand side Remove the wiring harness retainer bracket (12), undoing the indicated screw. Left-hand side Disconnect the pipes (13) and (14) from the plenum, removing the indicated clamps.
Page 638 Air intake manifold Page 5 of 18 Left-hand side Detach the connector (16) from the mounting bracket. Remove the wiring harness retainer bracket (17), undoing the indicated screws. Left-hand side Remove the wiring harness retainer brackets (18) and (19), undoing the indicated screws. Disconnect the quick connector (20) of the brake servo vacuum pipe.
Page 639 Air intake manifold Page 6 of 18 FROM Ass.ly No. 90802 _ Left hand side Open the clamps indicated. Open the indicated clamp fastening the pipes to the intake manifold. Right-hand side Undo the indicated upper screw fastening the three plastic clamps to the intake manifold.
Page 640 Air intake manifold Page 7 of 18 Left-hand side Undo the indicated upper screw fastening the two plastic clamps to the intake manifold. Undo the lower screw indicated fastening the injection cable retainer bracket to the intake manifold. Left-hand side Move the left hand injection cable (23) aside as far as possible to allow access to the intake manifold fasteners.
Page 641 Air intake manifold Page 8 of 18 Left-hand side Tilt the intake manifold slightly to the left in order to be able to remove the indicated clip fastening the power steering fluid pipes (24). Left-hand side Keeping the intake manifold tilted, remove the indicated clip fastening the power steering fluid pipes (24).
Page 642 Air intake manifold Page 9 of 18 Right-hand side Disconnect the connector (31) at the front of the intake manifold. With the assistance of another worker, lift the intake manifold off the engine. Remove the two gaskets (29) from the cylinder heads.
Page 643 Air intake manifold Page 10 of 18 Fit two new seals (29) in the relative seats on the cylinder heads. With the assistance of another worker, fit the intake manifold in the relative seat on the engine. Right-hand side Connect the connector (31) at the front of the intake manifold.
Page 644 Air intake manifold Page 11 of 18 Left-hand side Tilt the intake manifold slightly to the left in order to be able to fix the indicated clip, fastening the power steering fluid pipes (24), onto the metal bracket. Left-hand side Keeping the intake manifold tilted, fix the indicated clip, fastening the power steering fluid pipes (24), onto the metal bracket.
Page 645 Air intake manifold Page 12 of 18 Left-hand side Move the left hand injection cable (23) aside as far as possible in order to be able to tighten the intake manifold fasteners. Take particular care when fitting the intake manifold. Locating the manifold incorrectly may deform and compromise the tightness of the gaskets, causing the "Engine diagnostic system (EOBD)"...
Page 646 Air intake manifold Page 13 of 18 Right-hand side Loosen the lower screw indicated fastening the injection cable retainer bracket to the intake manifold. Tighten the indicated upper screw fastening the three plastic clamps to the intake manifold. Close the indicated clamp fastening the pipes to the intake manifold.
Page 647 Air intake manifold Page 14 of 18 Left-hand side Connect the quick connector (20) of the brake servo vacuum pipe. Fasten the wiring harness retainer brackets (18) and (19), tightening the indicated screws. FROM Ass.ly No. 90802 _ Left hand side Close the indicated clamps.
Page 648 Air intake manifold Page 15 of 18 Left-hand side Fasten the wiring harness retainer bracket (15), tightening the indicated screw. Connect and fasten the pipes (13) and (14) to the plenum, using new clamps as indicated. Right-hand side Fasten the wiring harness retainer bracket (12), tightening the indicated screw.
Page 649 Air intake manifold Page 16 of 18 Right-hand side Fasten the wiring harness retainer bracket (9), tightening the indicated screws. Right-hand side Fit and fasten the connector (8) on the mounting bracket. Right-hand side Connect and fasten the pipes (4) and (5) to the plenum, using new clamps as indicated.
Page 650 Air intake manifold Page 17 of 18 Right-hand side Connect and fasten the pipe (6) to the rigid pipe, using a new clamp as indicated. Fasten the vacuum pipe (7) to the plenum, tightening the indicated screw. FROM Ass.ly No. 91654 _ Right hand side Connect the pipe (32) to the tank.
Page 651 Air intake manifold Page 18 of 18 Connect and fasten the motorised throttle bodies to the plenums with new clamps (1). Connect the quick coupling (26) to the left hand bellow. Connect the pneumatic actuator system pipes (2) and fasten with a new clamp as indicated. Reconnect the battery ( F2.01).
Page 652 Engine lubrication system layout Page 1 of 1 Print Exit B5.01 Engine lubrication system layout Engine lubrication system layout A - Engine oil tank B - Engine oil pump C - Water/engine oil heat exchanger D - Engine oil filter...
Page 653 Engine oil pump Page 1 of 8 Print Exit B5.02 Engine oil pump Removing the oil pump The oil pump is mounted on the lower right hand side of the engine. Drain the engine lubrication system ( A3.01). Undo the indicated screw on the fork (1) retaining the pipe (2) on the oil pump (A).
Page 654 Engine oil pump Page 2 of 8 UP TO Engine No. 158940 Remove the Seeger ring (4) and push the bushing (5) down to detach from the orifice on the crankcase. FROM Engine No. 158941 Undo the indicated screws and remove the bracket (4).
Page 655 Engine oil pump Page 3 of 8 Supporting the weight of the pump and applying leverage with a suitably protected tool (6), move the oil pump (A) perpendicularly backwards, in order to detach the union bushing (7) from the crankcase. Remove the oil pump (A), complete with lower housing, from the engine.
Page 656 Engine oil pump Page 4 of 8 Tightening torque Class Fastening engine oil recovery and pick-up pipe Screw 10 Nm Oil pump - crankcase Screw 25 Nm Fastening oil pump bush retainer bracket Screw 10 Nm Before refitting the oil pump, replace all the gaskets as follows. Remove the mesh filter (14) from the relative seat on the lower housing of the engine oil tank and blow with compressed air to remove any...
Page 657 Engine oil pump Page 5 of 8 Replace and lubricate the gasket (10) on the oil pump. The tab at the centre of the gasket (10) must face downward and fasten onto the edge of the relative seat. Replace the two O-rings (11) on the union bushings. Replace and lubricate the two O-rings (12) on the hose leading from the engine oil tank.
Page 658 Engine oil pump Page 6 of 8 Fasten the flange (8) onto the oil pump (A), fitting the retainer fork (9) and tightening the screw indicated. Tightening torque Class Screw 10 Nm If the hexagonal bar was removed, during reassembly, ensure that the white paint marking on the bar itself is turned towards the timing side.
Page 659 Engine oil pump Page 7 of 8 Tighten the six screws indicated fastening the oil pump (A) onto the crankcase, in the sequence illustrated in the photo aside. Tightening torque Class Screw 25 Nm UP TO Engine No. 158940 Push the bushing (5) upward to insert fully in the crankcase, then fit the Seeger ring (4) in the relative seat.
Page 660 Engine oil pump Page 8 of 8 Fit the pipe (2) in the relative seat on the oil pump (A). Fit the fork (1) retaining the pipe (2) in its relative seat and fasten the assembly by tightening the indicated screw. Tightening torque Class Screw...
Page 661 Engine oil tank Page 1 of 8 Print Exit B5.03 Engine oil tank Removing the engine oil tank Remove the air flow meter ( F3.07). Remove both air flow meters. Remove the motorised throttle body ( F3.08). Remove both motorised throttle bodies. Drain the engine lubrication system ( A3.01).
Page 662 Engine oil tank Page 2 of 8 Open the indicated clamps to detach the power steering fluid pipes (4) and the secondary air pipe (5). Disconnect the pipe (3) from the engine oil tank (A). Disconnect the pipes (6) and (7) from the right hand intake manifold, removing the relative clamps and opening the indicated clamp.
Page 663 Engine oil tank Page 3 of 8 UP TO Ass.ly No. 92289 Remove the right hand tie-rod (8), undoing the screws (9) and (10). Undo the screw indicated on the fork (12) retaining the pipe (11) on the oil pump (13). Detach the pipe (11).
Page 664 Engine oil tank Page 4 of 8 Undo the indicated rear screws fastening the engine oil tank (A) to the gearbox. Undo the front left hand screw fastening the engine oil tank (A) to the gearbox. Undo the front right hand screw fastening the engine oil tank (A) to the gearbox.
Page 665 Engine oil tank Page 5 of 8 Tightening torque Class Fastening engine oil tank to gearbox Screw 10 Nm Fastening engine oil recovery and pick-up pipe Screw 10 Nm Fastening Tie-rod to gearbox Screw 88 Nm Fastening tie-rod to cylinder heads Screw 24 Nm Replace the two O-rings (14) on the hose and the O-...
Page 666 Engine oil tank Page 6 of 8 Tighten the front right hand screw fastening the engine oil tank (A) to the gearbox. Tightening torque Class Screw 10 Nm Tighten the front left hand screw fastening the engine oil tank (A) to the gearbox. Tightening torque Class Screw...
Page 667 Engine oil tank Page 7 of 8 Fit the pipe (11) in the relative seat on the oil pump (13). Fit the fork (12) retaining the pipe (11) in its relative seat and fasten the assembly by tightening the indicated screw. Tightening torque Class Screw...
Page 668 Engine oil tank Page 8 of 8 Connect the pipes (2) and (3) to the engine oil tank (A), fitting a new clamp. Close the indicated clamps fastening the power steering fluid pipes (4) and the secondary air pipe (5). Fit the valve (1) in the relative seat on the rear of the engine oil tank (A) and fasten by tightening the screws indicated.
Page 669 Water-engine oil heat exchanger Page 1 of 5 Print Exit B5.04 Water-engine oil heat exchanger Removing the engine oil-water heat exchanger There may be residual engine oil inside the heat exchanger. Clean/dry any pooling oil/water. Take particular care not to contaminate the two systems. The following photos show the engine removed from the vehicle to illustrate the procedure more clearly.
Page 670 Water-engine oil heat exchanger Page 2 of 5 Undo the screws indicated by the black arrows. Retrieve the bracket (1). Undo the stud bolts (2) fastening the clamps (3). Undo the screws indicated by the red arrows to release the clamps (3). Move the injection cable (4) away from over the heat exchanger so that it does not hinder the subsequent operations.
Page 671 Water-engine oil heat exchanger Page 3 of 5 Remove the gasket (9) from the heat exchanger (A) and replace. Remove the adhesive gasket (10) from the heat exchanger (A) and replace. Refitting the engine oil-water heat exchanger Tightening torque Class Fastening oil-water heat exchanger Screw 10 Nm...
Page 672 Water-engine oil heat exchanger Page 4 of 5 Thoroughly clean the mating faces on the crankcase in contact with the gasket (9). Thoroughly clean the mating faces on the heat exchanger (A) in contact with the gasket (9). Fit a new gasket (9). Thoroughly clean the mating faces on the heat exchanger (A) in contact with the adhesive gasket (10).
Page 673 Water-engine oil heat exchanger Page 5 of 5 Fit and fasten the water vent pipe (8), tightening the indicated union. Lay the engine services cable (7) as originally fitted on the heat exchanger. Place the injection cables (4) on top of the heat exchanger as originally fitted.
Page 674 Blow-by system Page 1 of 1 Print Exit B5.05 Blow-by system The oil vapour and gas recirculation system is a closed circuit. In the event of engine malfunction causing an anomalous increase in oil pressure, oil vapour from the heads is ducted via the pipes (A) to the vapour separator (B).
Page 675 Draining and filling the engine lubrication system Page 1 of 3 Print Exit B5.06 Draining and filling the engine lubrication system Draining the engine lubrication system Pour the oil drained from the system into a container and seal it. DO NOT dispose of used oil in the environment.
Page 676 Draining and filling the engine lubrication system Page 2 of 3 Tightening torque Class Magnetic oil drain plugs M22x1.5 plug 60 Nm Clean the oil drain plugs (1) and (2) thoroughly with a suitable degreaser that does not leave residue. Always replace the seals with new seals.
Page 677 Draining and filling the engine lubrication system Page 3 of 3 Fill the system with the prescribed type and quantity of oil (see "A1.02 _ Fluids and lubricants table"). The quantity of oil required may vary slightly relative to the amount indicated for filling the tank when empty;...
Page 678 Engine cooling system layout Page 1 of 1 Print Exit B6.01 Engine cooling system layout A - Expansion tank B - Water pump C - Radiators...
Page 679 Expansion tank Page 1 of 2 Print Exit B6.02 Expansion tank Removing the expansion tank Disconnect the battery ( F2.01). Remove the engine compartment cosmetic shields ( E3.13). Remove the right hand engine compartment shield. Remove the engine air ducts ( B4.02).
Page 680 Expansion tank Page 2 of 2 Fit the expansion tank (A) in the relative seat and fasten by tightening the screws indicated. Tightening torque Class Screw 8 Nm Fasten the clamp indicated by the red arrow, located on the front of the expansion tank (A). Connect the pipes and fasten with new clamps (3).
Page 681 Water pump Page 1 of 2 Print Exit B6.03 Water pump Removing the water pump The water pump is integrated in the front timing cover. Drain the engine lubrication system ( A3.01). Drain the cooling system ( B6.07). Remove the from timing cover ( B2.03).
Page 682 Water pump Page 2 of 2 On the workbench, replace and lubricate the two O- rings (1) on the pump, taking particular care not to damage the rings or the seal recesses. Ensure that the two O-rings (1) are installed correctly and are NOT twisted.
Page 683 Pressure switch/thermostat Page 1 of 1 Print Exit B6.04 Pressure switch/thermostat Replacing the pressure switch/thermostat Tightening torque Class Fastening hose union to thermostat Screw collar 4 Nm Drain the cooling system ( B6.07). Remove the engine inspection hatch ( E4.06). Loosen the clamp (1) and detach the pipe (2) from the pressure switch/thermostat (A).
Page 684 Water radiators Page 1 of 12 Print Exit B6.05 Water radiators Removing the water radiators Drain the cooling system ( B6.07). If only one radiator needs to be removed, drain that radiator only. Left hand radiator Remove the condenser ( F5.04).
Page 685 Water radiators Page 2 of 12 Disconnect the connector (1). Disconnect the connectors (2). Loosen the clamp (3) fastening the pipe union (C) to the water radiator (D). Disconnect the pipe union (C) from the water radiator (D). Place a suitably sized container under the pipe union (C) to collect any coolant leakage.
Page 686 Water radiators Page 3 of 12 Undo the indicated front screw fastening the water radiator (D) and retrieve the relative washer and mounting. Supporting the weight of the water radiator (D), undo the indicated rear screw fastening the water radiator (D) and retrieve the relative washer and mounting.
Page 687 Water radiators Page 4 of 12 Right hand radiator Remove the radiator/power steering fluid coil ( D5.05). Remove the water radiator without disconnecting the power steering system pipes. Undo the indicated screw fastening the front brake air duct (A). Remove the front brake air duct (A) from the relative seat.
Page 688 Water radiators Page 5 of 12 Disconnect the connector (1). Disconnect the connectors (2). Loosen the clamp (3) fastening the pipe union (C) to the water radiator (D). Disconnect the pipe union (C) from the water radiator (D). Place a suitably sized container under the pipe union (C) to collect any coolant leakage.
Page 689 Water radiators Page 6 of 12 Undo the indicated front screw fastening the water radiator (D) and retrieve the relative washer and mounting. Supporting the weight of the water radiator (D), undo the indicated rear screw fastening the water radiator (D) and retrieve the relative washer and mounting.
Page 690 Water radiators Page 7 of 12 Refitting the water radiators Tightening torque Class Fastening water radiators Screw 25 Nm Fastening upper radiator air ducts Screw 6 Nm Fastening front brake air ducts Screw 5 Nm Check the radiators for fouling ( A3.32).
Page 691 Water radiators Page 8 of 12 Fit the relevant washer and mounting and tighten the indicated front screw fastening the water radiator (D). Tightening torque Class Screw 25 Nm Remove the plug from the water radiator (D). Connect the pipe union (C) to the water radiator (D). Tighten the clamp (3) fastening the pipe union (C) to the water radiator (D).
Page 692 Water radiators Page 9 of 12 Connect the connector (1). Fit the upper radiator air duct (B) in the relative seat. Tighten the indicated screws fastening the upper radiator air duct (B). Tightening torque Class Screw 6 Nm Fit the front brake air duct (A) in the relative seat. Tighten the indicated screw fastening the front brake air duct (A).
Page 693 Water radiators Page 10 of 12 Right hand radiator Fit the water radiator in the relative seat. Supporting the weight of the water radiator (D), fit the relevant washer and mounting, and tighten the indicated lateral screw fastening the water radiator (D).
Page 694 Water radiators Page 11 of 12 Remove the plug from the water radiator (D). Connect the pipe union (C) to the water radiator (D). Tighten the clamp (3) fastening the pipe union (C) to the water radiator (D). Connect the connectors (2). Connect the connector (1).
Page 695 Water radiators Page 12 of 12 Fit the upper radiator air duct (B) in the relative seat. Tighten the indicated screws fastening the upper radiator air duct (B). Tightening torque Class Screw 6 Nm Fit the front brake air duct (A) in the relative seat. Tighten the indicated screw fastening the front brake air duct (A).
Page 696 Electric fans Page 1 of 2 Print Exit B6.06 Electric fans Removing the electric fans Remove the water radiators ( B6.05). Only remove the water radiator on which the relative electric fan is mounted. Undo the four screws indicated fastening the electric fan (A) to the water radiator.
Page 697 Electric fans Page 2 of 2 Fit the electric fan (A) in the relative seat. Tighten the four screws indicated fastening the electric fan (A) to the water radiator. Tightening torque Class Screw 5 Nm Refit the water radiators ( B6.05).
Page 698 Draining and filling the engine cooling system Page 1 of 5 Print Exit B6.07 Draining and filling the engine cooling system Draining the cooling system CAUTION ALWAYS WORK WHEN THE ENGINE IS COLD. The fluid contained in the cooling system reaches extremely high temperatures; take the necessary precautions to prevent burns.
Page 699 Draining and filling the engine cooling system Page 2 of 5 UP TO Ass.ly No. 90801 _ Left hand side Disconnect the temperature sensor connector (3). Undo the screw indicated fastening the rigid pipe Loosen the clamps (4) fastening the connector pipe (5) onto the rigid pipes.
Page 700 Draining and filling the engine cooling system Page 3 of 5 CAUTION The fluid contained in the cooling system reaches extremely high temperatures and pressure. ALWAYS WORK WHEN THE ENGINE IS COLD. Check that all the connection sleeve clamps are tight. Static filling (engine off) Remove the engine compartment cosmetic shields ( E3.13).
Page 701 Draining and filling the engine cooling system Page 4 of 5 05) Screw plug (1) onto expansion tank. 06) Check that heater circuit is off. 07) Start engine at idle speed and wait for 5 minutes. 08) Keep engine running at idle speed, check level and, if necessary, top up until MAX level. 09) Take and keep engine at 2000 rpm for 30 seconds.
Page 702 Draining and filling the engine cooling system Page 5 of 5 29) If necessary, top up until reaching the point where fluid level in header tank is 60 mm from filler plug top (1) (MAX level). Tighten the cap (1). Refit the engine compartment cosmetic shields ( E3.13).
Page 703 Exhaust system layout Page 1 of 1 Print Exit B7.01 Exhaust system layout A - Manifolds B - Catalytic converters C - Silencers D - Silencer joint...
Page 704 Exhaust manifold Page 1 of 9 Print Exit B7.02 Exhaust manifold Removing the exhaust manifold The following process is for removing the left hand exhaust manifold. The differences in the procedure for removing the right hand exhaust manifold will be indicated in the instructions.
Page 705 Exhaust manifold Page 2 of 9 Working from above, undo the two indicated screws fastening the heat shield (4). Working from the wheel bay, undo the indicated screw. Remove the heat shield (4) via the wheel bay. If necessary, the heat shield (4) may be bent slightly to facilitate the operation.
Page 706 Exhaust manifold Page 3 of 9 Right hand exhaust manifold Fit the template 8257) on the flexible part of the exhaust manifold, as shown in the photo aside. Fasten the lug (11) onto the relative hook to secure the template 8257).
Page 707 Exhaust manifold Page 4 of 9 Remove the secondary air pipe and retrieve the relative seals (5) on the exhaust manifold and valve. Applicable for left hand exhaust manifold only Undo the indicated screw and retrieve the heat shield (6) protecting the compressor. Undo the eight nuts (7) fastening the exhaust manifold (A) to the cylinder head.
Page 708 Exhaust manifold Page 5 of 9 Retrieve the gasket (8) from the exhaust manifold. Refitting the exhaust manifold Tightening torque Class Fastening exhaust manifolds to cylinder heads 25 Nm Fastening A.C. compressor heat shield Screw 9 Nm Oxygen sensors Oxygen sensor 50 Nm Check that the gasket mating surfaces on the head and the manifold are perfectly flat;...
Page 709 Exhaust manifold Page 6 of 9 Fit and fasten the exhaust manifold (A) to the cylinder head, hand-tightening the eight nuts (7). Tighten the eight nuts in the sequence indicated in the figure aside. Tightening torque Class 25 Nm Applicable for left hand exhaust manifold only Fit and fasten the compressor heat shield (6), tightening the screw indicated.
Page 710 Exhaust manifold Page 7 of 9 Fit new gaskets (5) on the exhaust manifold and valve. Fit the secondary air pipe (3) in the relative seat and fasten to the valve/mounting bracket by tightening the two screws indicated. Hand tighten the screws indicated fastening the secondary air pipe (3) to the exhaust manifold.
Page 711 Exhaust manifold Page 8 of 9 Applicable for right hand exhaust manifold ONLY Working from the wheel bay, fit the heat shield (4). Hand tighten the indicated screw. If necessary, bend the heat shield (4) back into the original shape. Applicable for right hand exhaust manifold ONLY Working from above, tighten the two indicated screws fastening the heat shield (4).
Page 712 Exhaust manifold Page 9 of 9 Fit and tighten the oxygen sensor (1) on the exhaust manifold (A). Tightening torque Class Oxygen sensor 50 Nm Applicable for left hand exhaust manifold only. Refit the compressor ( F5.03). Adjust the exhaust system ( B7.04).
Page 713 Catalytic converter Page 1 of 7 Print Exit B7.03 Catalytic converter Removing the catalytic converter The following procedure is for removing the left hand catalytic converter. The procedure for removing the right hand catalytic converter is identical. Remove the rear diffuser ( E3.12).
Page 714 Catalytic converter Page 2 of 7 Apply AREXONS SVITOL TECHNIK SILIKON SPRAY to the joint between the catalytic converter and the silencer, leaving the product to act for a few minutes. Loosen the Torx clamp (2) fastening the catalytic converter (A) to the silencer (3). If present, remove shield (9) by loosening the indicated screws.
Page 715 Catalytic converter Page 3 of 7 Undo the two screws indicated fastening the catalytic converter mounting bracket (7). For left hand catalytic converter ONLY Working from above, undo the two indicated screws fastening the heat shield (10). For left hand catalytic converter ONLY Working from the wheel bay, undo the indicated screw.
Page 716 Catalytic converter Page 4 of 7 Left hand catalytic converter Fit the template 8257) on the flexible part of the exhaust manifold, as shown in the photo aside. Fasten the lug (11) onto the relative hook to secure the template 8257).
Page 717 Catalytic converter Page 5 of 7 Tightening torque Class Fastening catalytic converter mounting brackets to Screw 25 Nm chassis Oxygen sensors Oxygen sensor 50 Nm NEVER reuse exhaust system clamps that have been subjected to operating temperature. Replace with new components. Removal and refitting is only permitted with new clamps for adjustment purposes during initial installation.
Page 718 Catalytic converter Page 6 of 7 Fasten the catalytic converter mounting bracket (7) to the chassis, tightening the screws indicated. Tightening torque Class Screw 25 Nm Fit the air flow meter - motorised throttle body assembly in the relative seat. Tighten the two nuts indicated fastening the air flow meter to the air box (6).
Page 719 Catalytic converter Page 7 of 7 NEVER reuse exhaust system clamps that have been subjected to operating temperature. Replace with new components. Removal and refitting is only permitted with new clamps for adjustment purposes during initial installation. Partially tighten the clamp (2) fastening the catalytic converter (A) to the silencer (3), by tightening the relative nut.
Page 720 Silencers Page 1 of 20 Print Exit B7.04 Silencers Removing the silencers Remove the rear bumper ( E3.04). Right hand silencer Disconnect the pipe (1) from the By-pass valve of the silencer. Loosen the clamps (2) fastening the central exhaust pipe (A) to the silencers (B), undoing the relative nuts indicated.
Page 721 Silencers Page 2 of 20 Undo the indicated nut fastening the lateral mounting bushing for the silencer. Support the weight of the silencer adequately. Undo the indicated nuts fastening the mounting bushings for the silencer (B). Loosen the clamp (3) fastening the silencer (B) to the catalytic converter (C), loosening the relative nut.
Page 722 Silencers Page 3 of 20 Disconnect the pipe (1) from the By-pass valve of the silencer. Loosen the clamps (2) fastening the central exhaust pipe (A) to the silencers (B), undoing the relative nuts indicated. Disconnect and remove the central exhaust pipe (A) from the silencers (B).
Page 723 Silencers Page 4 of 20 Support the weight of the silencer adequately. Undo the indicated nuts fastening the mounting bushings for the silencer (B). Loosen the clamp (3) fastening the silencer (B) to the catalytic converter (C), loosening the relative nut.
Page 724 Silencers Page 5 of 20 NEVER reuse exhaust system clamps that have been subjected to operating temperature. Replace with new components. Removal and refitting is only permitted with new clamps for adjustment purposes during initial installation. Fit the right hand silencer (B) in the relative seat and connect to the right hand catalytic converter (C).
Page 725 Silencers Page 6 of 20 NEVER reuse exhaust system clamps that have been subjected to operating temperature. Replace with new components. Removal and refitting is only permitted with new clamps for adjustment purposes during initial installation. Connect the central exhaust pipe (A) to the silencers (B).
Page 726 Silencers Page 7 of 20 Support the weight of the silencer adequately. Partially tighten the indicated nuts fastening the rear mounting bushings for the left hand silencer (B). Partially tighten the indicated nut fastening the lateral mounting bushing for the left hand silencer.
Page 727 Silencers Page 8 of 20 Connect the pipe (1) to the By-pass valve of the left hand silencer. Adjust the exhaust system ( B7.04). Adjusting the exhaust system Tightening torque Class Fastening catalytic converters to exhaust manifolds Clamp 13 Nm Fastening centre exhaust pipe to silencers Clamp (pretightening) 25 Nm...
Page 728 Silencers Page 9 of 20 If present, remove shield (1) by loosening the indicated screws. If present, remove shield (1) by loosening the indicated screws. Loosen the indicated nut.
Page 729 Silencers Page 10 of 20 Loosen the indicated nuts. Loosen the indicated nut. Loosen the indicated nuts.
Page 730 Silencers Page 11 of 20 Loosen the indicated screws. Loosen the indicated screws. Loosen the indicated clamp.
Page 731 Silencers Page 12 of 20 Loosen the indicated clamp. Loosen the indicated clamps. for the left hand cylinder bank exhaust ONLY Working from above, undo the two indicated screws fastening the heat shield (10).
Page 732 Silencers Page 13 of 20 for the left hand cylinder bank exhaust ONLY Working from the wheel bay, undo the indicated screw. Remove the heat shield (10) via the wheel bay. If necessary, the heat shield (10) may be bent slightly to facilitate the operation.
Page 733 Silencers Page 14 of 20 Check that the central exhaust pipe (A) is spaced equally between the two silencer exhaust pipes (B) and that it is parallel with the ground. If not, adjust as necessary to meet the conditions described above. With the template 8257) still fixed to the flexible exhaust manifold pipe, tighten the clamp (8).
Page 734 Silencers Page 15 of 20 Pre-tighten the indicated clamps. Tightening torque Class Clamp (pretightening) 25 Nm Pre-tighten the indicated clamp. Tightening torque Class Clamp (pretightening) 25 Nm Pre-tighten the indicated clamp. Tightening torque Class Clamp (pretightening) 25 Nm...
Page 735 Silencers Page 16 of 20 Tighten the screws indicated. Fasten the catalytic converter mounting bracket first and then fasten the catalytic converter to the relative bushings. Tightening torque Class Screw 25 Nm Screw / Nut 25 Nm Tighten the screws indicated. Fasten the catalytic converter mounting bracket first and then fasten the catalytic converter to the relative bushings.
Page 736 Silencers Page 17 of 20 Tighten the indicated nut. Tightening torque Class 13 Nm Tighten the nuts indicated. Tightening torque Class 13 Nm Tighten the indicated nut. Tightening torque Class 13 Nm...
Page 737 Silencers Page 18 of 20 Tighten the indicated clamp. Tightening torque Class Clamp +6.5 54.2 -6.5 Tighten the indicated clamp. Tightening torque Class Clamp +6.5 54.2 -6.5 Tighten the indicated clamps. Tightening torque Class Clamp +6.5 54.2 -6.5...
Page 738 Silencers Page 19 of 20 for the left hand cylinder bank exhaust ONLY Working from the wheel bay, fit the heat shield (10). Hand tighten the indicated screw. If necessary, bend the heat shield (10) back into the original shape. for the left hand cylinder bank exhaust ONLY Working from above, tighten the two indicated screws fastening the heat shield (10).
Page 739 Silencers Page 20 of 20 If present, position shield (1). Hand tighten the screws indicated. Refit the rear bumper ( E3.04). Refit the rear wheelhouses ( E3.05). Refit the engine compartment cosmetic shields ( E3.13).
Page 740 Technical specifications Page 1 of 2 Print Exit C1.01 Technical specifications Gear ratios Transmission 3.077 2.185 1.626 1.286 1.028 0.839 0.693 2.791 gear ratios Bevel gear 5.143 pair/differential ratio General New dual clutch gearbox with 7 forward speeds + reverse and F1 shift paddles, chosen to offer the driving pleasure of a sequential gearbox together with the comfort of an automatic gearbox.
Page 741 Technical specifications Page 2 of 2 drives the even gears, the other drives the odd gears. While one primary shaft transmits torque to 1st gear, 2nd gear is already engaged on the other primary shaft. Gear shifting is achieved by opening one clutch while simultaneously closing the other. The results of this are shift times close to zero (sportiness), seamless torque delivery (performance) and shifts as smooth as an automatic transmission (comfort).
Page 742 Specific tooling and equipment Page 1 of 3 Print Exit C1.02 Specific tooling and equipment Trolley 95977565 (AS 107565) removing the engine / gearbox / subframe assembly. Trolley 95977572 (AS 107572) to be used together with trolley AS 107565 for removing/refitting gearbox from and into vehicle.
Page 743 Specific tooling and equipment Page 2 of 3 Torque wrench 95978172 (AV 8172) (Replaces torque wrench USAG 815F) Hook 95977564 (AS 107564) for lifting the gearbox. Pump 95978174 (AV 8174) topping up gearbox and clutch oil.
Page 744 Specific tooling and equipment Page 3 of 3 Engine retainer bracket for gearbox removal 95978254 (AV 8254) removing the gearbox.
Page 745 Tightening torques Page 1 of 1 Print Exit C1.03 Tightening torques Tightening torque Class Fastening gearbox oil filler/drain plug and clutch Plug 25 Nm hydraulic fluid filler/drain plug Fastening Tie-rod to gearbox Screw 88 Nm Fastening tie-rod to cylinder heads Screw 24 Nm Fastening starter motor to gearbox...
Page 746 Gear oil system layout Page 1 of 1 Print Exit C2.01 Gear oil system layout Gear oil system layout A - DCT gearbox (gear oil tank and gear oil pump) B - Gear oil pipes C - Water/gear oil radiator...
Page 747 Removing the complete DCT gearbox Page 1 of 13 Print Exit C2.02 Removing the complete DCT gearbox Removing the complete gearbox CAUTION For safety reasons, the VEHICLE MAY ONLY BE LIFTED WITH THE ANTI-TIPPING SAFETY RETAINERS INSTALLED. Remove the rear diffuser ( E3.12).
Page 748 Removing the complete DCT gearbox Page 2 of 13 Before starting the following procedure, the trolley 107565) must be configured correctly for removing the gearbox on this vehicle. Undo the indicated screws fastening the telescoping arm (17) to the relevant mounting (18) on all the arms on the trolley 107565).
Page 749 Removing the complete DCT gearbox Page 3 of 13 Release the drain pipe (23) from the rubber lined bracket by undoing the indicated screw. FROM Ass.ly No. 96750 (see Spare Parts Catalogue to see vehicles not affected by modification) Release the drain pipe (23) from the rubber lined bracket by undoing the indicated screw.
Page 750 Removing the complete DCT gearbox Page 4 of 13 Remove the shield (1), undoing the indicated nuts. Undo the screws indicated fastening the heat shield (2). Remove the heat shield (2), undoing the screw indicated. FROM Ass.ly No. 92290 Remove the heat shield (2), undoing the screw indicated.
Page 751 Removing the complete DCT gearbox Page 5 of 13 Clean the area surrounding the fastener point for the clutch hydraulic system oil pipes thoroughly using a suitable degreaser that does not leave residue. Place a container for collecting the clutch hydraulic system oil under the pipes.
Page 752 Removing the complete DCT gearbox Page 6 of 13 Fit the tool 8254) onto the rear subframe to support the weight of the engine and prevent it from tipping when the gearbox is removed. Fit the tool in the relevant seat and fasten by tightening the two screws indicated;...
Page 753 Removing the complete DCT gearbox Page 7 of 13 UP TO Ass.ly No. 92289 Remove the left hand tie-rod (12), undoing the screws (10) and (11). Fit a hydraulic jack under the gearbox and lift it slightly, placing it under tension, in order to facilitate the removal of the pin (22).
Page 754 Removing the complete DCT gearbox Page 8 of 13 Position the trolley 107565) under the vehicle and lift the platform to approximately 10 mm from the adjuster pins. Loosen the nut (19) then unscrew the pin (20) of tool 107572), until the pin comes into contact with the trolley 107572).
Page 755 Removing the complete DCT gearbox Page 9 of 13 Undo the four lower nuts (14) fastening the gearbox (A) to the engine (B). Undo the screws indicated fastening the starter motor (13) to the gearbox. Unscrew the indicated screws fastening the lower gearbox mounting cross-member (9).
Page 756 Removing the complete DCT gearbox Page 10 of 13 FROM Ass.ly No. 96750 (see Spare Parts Catalogue to see vehicles not affected by modification) Unscrew the indicated screws fastening the lower gearbox mounting cross-member (9). Unscrew the indicated screws and remove the lower gearbox mounting cross-member (9).
Page 757 Removing the complete DCT gearbox Page 11 of 13 Loosen the two trolley platform locking handles 107565) and move the trolley 107572) to ease the gearbox (A) off the engine stud bolts. After easing out the gearbox (A), lock the two trolley platform lock handles 107565).
Page 758 Removing the complete DCT gearbox Page 12 of 13 Undo the screws indicated and remove the cover (1). Remove the gearbox mounting bushing (A) from the cover (1) and replace it. Fit a new gearbox mounting bushing (A) inserting the indicated pin inside the relative seat on the cover (1).
Page 759 Removing the complete DCT gearbox Page 13 of 13 Fasten the cover (1) tightening the indicated screws, and following the sequence shown in the photo. Tightening torque Class Screw 30 Nm Refit the complete gearbox ( C2.03).
Page 760 Refitting the complete DCT gearbox Page 1 of 11 Print Exit C2.03 Refitting the complete DCT gearbox Refitting the complete gearbox Tightening torque Class Fastening lower gearbox mounting cross member Screw 60 Nm to chassis Fastening gearbox to engine 60 Nm Fastening starter motor to gearbox Screw 25 Nm...
Page 761 Refitting the complete DCT gearbox Page 2 of 11 Apply a layer of copper grease Copper Grease ROLOIL on the splined shaft of the gearbox. Supporting the weight of the gearbox adequately with the lift trolley 107565) and the trolley 107572), position the complete gearbox (A) under the engine compartment, aligned with the engine stud bolts.
Page 762 Refitting the complete DCT gearbox Page 3 of 11 FROM Ass.ly No. 96750 (see Spare Parts Catalogue to see vehicles not affected by modification) Apply AREXONS SYSTEM 52A43 - MEDIUM STRENGTH THREAD LOCK on the thread of the screws indicated. Fit the lower gearbox mounting cross-member (9) in its seat and hand-tighten the indicated screws.
Page 763 Refitting the complete DCT gearbox Page 4 of 11 Tighten the indicated screws fastening the lower gearbox mounting cross member (9), following the sequence shown in the photo. Tightening torque Class Screw 60 Nm FROM Ass.ly No. 96750 (see Spare Parts Catalogue to see vehicles not affected by modification) Tighten the indicated screws fastening the lower gearbox mounting cross member (9), following...
Page 764 Refitting the complete DCT gearbox Page 5 of 11 Fit and tighten the four lower nuts (14) fastening the complete gearbox (A) to the engine (B). Tightening torque Class 60 Nm Tighten the screws indicated fastening the starter motor (13) to the gearbox. Tightening torque Class Screw...
Page 765 Refitting the complete DCT gearbox Page 6 of 11 Fit a hydraulic jack under the gearbox and lift it slightly, placing it under tension, in order to facilitate the fitting of the pin (22). Fit the pin (22) fastening the bushing mounting (15) to the rear subframe, after fitting the washer.
Page 766 Refitting the complete DCT gearbox Page 7 of 11 UP TO Ass.ly No. 92289 Fit the left hand tie-rod (12) and fasten by tightening the screws (10) e (11). Tightening torque Class Screw 88 Nm Screw 24 Nm Loosen the nut (C), then unscrew the pin (D) by a few turns.
Page 767 Refitting the complete DCT gearbox Page 8 of 11 Fit the mounting bracket (7) on the gearbox stud bolts and fasten the oil pipes of both systems onto the relevant pillory blocks. Clean the area surrounding the gear oil pipe fastener point thoroughly with a suitable degreaser that does not leave residue.
Page 768 Refitting the complete DCT gearbox Page 9 of 11 Fit and fasten the heat shield (2), tightening the screw indicated. FROM Ass.ly No. 92290 Fit and fasten the heat shield (2), tightening the screw indicated. Tighten the screws indicated fastening the heat shield (2).
Page 769 Refitting the complete DCT gearbox Page 10 of 11 Fasten the drain pipe (23) inside the rubber lined brackets tightening the indicated screws. Fasten the drain pipe (23) inside the rubber lined bracket tightening the indicated screw. FROM Ass.ly No. 96750 (see Spare Parts Catalogue to see vehicles not affected by modification) Fasten the drain pipe (23) inside the rubber lined bracket tightening the indicated screw.
Page 770 Refitting the complete DCT gearbox Page 11 of 11 Inspect the hydraulic clutch system oil level Shell DCT F-3 ( A3.03). Check the Shell Transaxle 75W-90 GL5 gear oil level ( A3.02). Lower the vehicle using anti-tipping safety retainers ( E3.12).
Page 771 Gear oil radiator Page 1 of 4 Print Exit C2.04 Gear oil radiator Removing gear oil radiator The gear oil radiator is located on the rear right-hand side of the vehicle, in front of the rear bumper. Remove the rear bumper ( E3.04).
Page 772 Gear oil radiator Page 2 of 4 Undo the indicated nuts and remove the gear oil radiator (A) from the vehicle. If necessary, separate the duct (3) from the gear oil radiator, undoing the indicated screws. Refitting gear oil radiator Tightening torque Class Fastening gear oil and clutch oil radiator to chassis Nut...
Page 773 Gear oil radiator Page 3 of 4 Check the state of the foam rubber pads (4); replace with new components if necessary. If removed, fit the duct (3) on the gear oil radiator, tightening the indicated screws. Fit the gear oil radiator (A) in the relative seat in the vehicle and fasten by tightening the indicated nuts.
Page 774 Gear oil radiator Page 4 of 4 Clean the inlet area of the unions (2) on the radiator with a suitable degreaser that does not leave residues. Remove the plugs positioned previously. Tighten the unions (2) on the gear oil radiator (A), using the markings made during removal as reference.
Page 775 Draining and filling with Shell Transaxle 75W-90 GL5 gear oil Page 1 of 2 Print Exit C2.05 Draining and filling with Shell Transaxle 75W-90 GL5 gear oil Draining the Shell Transaxle 75W-90 GL5 gear oil The gear oil must be changed at the intervals specified in the MAINTENANCE SCHEDULE. Remove the rear flat undertray section ( E3.12).
Page 776 Draining and filling with Shell Transaxle 75W-90 GL5 gear oil Page 2 of 2 Clean the plugs (1) and (2) thoroughly with a suitable degreaser that does not leave residue, and replace the seals. Tighten the plugs (1) and (2). Tightening torque Class Plug...
Page 777 Hydraulic clutch oil system layout Page 1 of 1 Print Exit C3.01 Hydraulic clutch oil system layout Hydraulic clutch oil system layout A - DCT gearbox (clutch oil tank and clutch oil pump) B - Clutch oil pipes C - Clutch oil radiator...
Page 778 Hydraulic clutch oil system radiator Page 1 of 5 Print Exit C3.02 Hydraulic clutch oil system radiator Removing the clutch hydraulic system oil radiator The clutch hydraulic system oil radiator is located on the rear left-hand side of the vehicle, in front of the rear bumper.
Page 779 Hydraulic clutch oil system radiator Page 2 of 5 Undo the indicated nuts and remove the clutch hydraulic system oil radiator (A) from the vehicle. Detach the connector (5) of the electric fan. If necessary, separate the duct (3) from the clutch hydraulic system oil radiator, undoing the indicated screws.
Page 780 Hydraulic clutch oil system radiator Page 3 of 5 Check the state of the foam rubber pads (4); replace with new components if necessary. If removed, fit the duct (3) on the clutch hydraulic system oil radiator, tightening the indicated screws.
Page 781 Hydraulic clutch oil system radiator Page 4 of 5 Clean the inlet area of the unions (2) on the radiator with a suitable degreaser that does not leave residues. Remove the plugs positioned previously. Tighten the unions (2) on the clutch hydraulic system oil radiator (A), using the markings made during removal as reference.
Page 782 Hydraulic clutch oil system radiator Page 5 of 5 Disconnect the connector (1). Undo the nuts indicated. Remove the electric fan (A) and replace. Fit the new electric fan (A) on the radiator. Tighten the nuts indicated. Tightening torque Class 4 Nm Connect the connector (1).
Page 783 Draining and filling with Shell DCT F-3 hydraulic clutch system oil Page 1 of 3 Print Exit C3.03 Draining and filling with Shell DCT F-3 hydraulic clutch system oil Draining Shell DCT F-3 hydraulic clutch system oil Remove the rear flat undertray section ( E3.12).
Page 784 Draining and filling with Shell DCT F-3 hydraulic clutch system oil Page 2 of 3 Clean the plug (1) thoroughly with a suitable degreaser that does not leave residue and replace the seal. Tighten the plug (1). Tightening torque Class Plug 25 Nm Undo the threaded inspection plug (2), located on...
Page 785 Draining and filling with Shell DCT F-3 hydraulic clutch system oil Page 3 of 3 Fill with half of the quantity indicated, wait a few minutes for the oil to settle, then gradually finish filling, until oil overflows from the level pipe (8). The quantity of oil required may vary slightly relative to the amount indicated for filling the tank when empty;...
Page 786 Axle shafts Page 1 of 6 Print Exit C4.01 Axle shafts Removing the axle shaft The following procedure is for the removal of the right hand axle shaft. The procedure for removing the left hand axle shaft is similar. Disable the EPB electric parking brake Autohold function ( D3.07).
Page 787 Axle shafts Page 2 of 6 Undo the nut (5), removing the relevant pin fastening the toe-in tie-rod (B) to the hub carrier (C). Support the weight of the rear suspension adequately and undo the nut (6), removing the relevant pin fastening the upper arm (D) to the hub carrier (C).
Page 788 Axle shafts Page 3 of 6 Left hand axle shaft Press on the two indicated fastener tabs and remove the left hand EPB Bowden cable sheath (9) from the relative mounting bracket. Tilt the hub carrier outward to detach the axle shaft from the differential flange. If necessary, cut the cable retainer clamps to slacken any tension preventing the hub carrier from tilting.
Page 789 Axle shafts Page 4 of 6 Apply three even and regularly spaced circular beads of AREXONS SYSTEM 56A01 - HIGH STRENGTH RETAINING COMPOUND. Fit the axle shaft in the hub carrier bearing. Tilt the hub carrier inward to bring the axle shaft and the differential flange together. Fit new cable retainer clamps if the previous clamps were cut.
Page 790 Axle shafts Page 5 of 6 Tighten the six screws (3) fastening the axle shaft (A) to the differential flange, fitting the three shims (4). Tightening torque Class Screw 78 Nm Tighten the ring nut (2) fastening the axle shaft to the hub carrier bearing.
Page 791 Axle shafts Page 6 of 6 Left hand axle shaft Press on the two indicated fastener tabs and fit the left hand EPB Bowden cable sheath (9) into the relative mounting bracket. Attach the end (8) of the left hand EPB Bowden cable (9) to the EPB linkage bracket.
Page 792 Flywheel Page 1 of 2 Print Exit C4.02 Flywheel Removing the flywheel Located inside the transmission housing and connected to the crankshaft. Remove the complete gearbox ( C2.02). Immobilise the crankshaft. Undo the eight screws indicated fastening the engine flywheel (A). Undo the screws in a crossed pattern, by undoing one screw first and then the opposite screw.
Page 793 Flywheel Page 2 of 2 Fit the engine flywheel (A) in its seat, aligning the crankshaft bearing and matching up the fastener holes. The flywheel can only be installed one way, as one of the eight holes is not centred, as on the crankshaft.
Page 794 Technical specifications Page 1 of 3 Print Exit D1.01 Technical specifications Brake system 390 mm x 36 mm carbon-ceramic front disc with 4-piston aluminium calliper 350 mm x 32 mm carbon-ceramic rear disc with 4-piston aluminium calliper 148 T4300 pads (front) 77 S600 pads (rear) Electric parking brake (EPB) Can be inserted and removed using a control on the dashboard.
Page 795 295/35 ZR20 Bridgestone Potenza 295/35 ZR20 Michelin Pilot Sport 2, interchangeable individually or in pairs with Michelin Pilot Super Sport (only in size indicated for 458 Italia) 295/35 ZR20 Michelin Pilot Super Sport 295/35 ZR20 Bridgestone Potenza Run Flat optional Run Flat...
Page 796 Technical specifications Page 3 of 3 Front Rear Bridgestone Potenza 33.36 psi 36.26 psi (Run Flat) Pirelli Winter 30.46 psi 29 psi Sottozero Vredestein (Spare 60.92 psi 60.92 psi wheel)
Page 797 Specific tooling and equipment Page 1 of 1 Print Exit D1.02 Specific tooling and equipment Support 95973206 (AV 3206) for complete hub. Torque wrench 95978172 (AV 8172) (Replaces torque wrench USAG 815F)
Page 798 Tightening torques Page 1 of 3 Print Exit D1.03 Tightening torques Tightening torque Class Fastening rigid pipe to power steering pump Union 37 Nm Fastening power steering pump to engine Screw 25 Nm Fastening cover to power steering pump Screw 10 Nm Fastening power steering fluid pipes to reservoir Screw collar...
Page 799 Tightening torques Page 2 of 3 Tightening torque Class Fastening shock absorber to lower arm Screw 80 Nm Fastening shock absorber to chassis Screw 110 Nm Fastening upper arm to chassis Nut (pretightening) 9 Nm 60 Nm Fastening toe-in tie-rod to chassis Nut (pretightening) 9 Nm 60 Nm...
Page 800 Tightening torques Page 3 of 3 Tightening torque Class Fastening electrohydraulic ABS/ASR unit Screw 24 Nm mounting bracket to chassis Fastening electrohydraulic ABS/ASR unit to Screw 18 Nm mounting bracket Fastening air duct on heater/evaporator unit inside Screw 1.5 Nm luggage compartment Fastening brake servo - pedal board 20 Nm...
Page 801 Complete wheel Page 1 of 3 Print Exit D2.01 Complete wheel Removing the wheels CAUTION Before performing any maintenance on vehicles with the Stop&Start system, turn the ignition key to 0. Before performing any maintenance procedures requiring the ignition key to be in position II on vehicles with the Stop&Start system, deactivate the Stop&Start system with the relative button, ensuring that the specific icon and the message "Stop&Start OFF"...
Page 802 Complete wheel Page 2 of 3 Check the state of wear of the tyre and the state of the wheel rim. When replacing a tyre or rim, the wheel must be statically and dynamically balanced. Check that the mating surfaces on the rim and brake disc are perfectly clean. Replace any stud bolts with damage to the thread or cone.
Page 803 Complete wheel Page 3 of 3 Fit the complete wheel, inserting the locator pin in the seat on the wheel rim. Hand tighten the stud bolt opposite the locator pin first, then the others. Pretighten the stud bolts in a crossed pattern. Tightening torque Class Pretightening of stud bolt...
Page 804 Tyres and rims Page 1 of 11 Print Exit D2.02 Tyres and rims Checking the state of the tyres Tyre replacement is recommend after 4 years of normal use. Frequent use in maximum load conditions and at high temperatures may lead to premature deterioration. Check the state of the tyres during the scheduled maintenance.
Page 805 Tyres and rims Page 2 of 11 CAUTION Never fit a tyre with tread depth under the specified limit, even if only in a single localised area. Check the tread depth: the minimum permissible value is 1.7 mm. This depth is identified by the tyre wear indicators.
Page 806 Tyres and rims Page 3 of 11 Temperature The temperature grades are "A" (the highest), "B", and "C", representing the tyre's resistance to the generation of heat and its ability to dissipate heat when tested under controlled conditions on a specified indoor laboratory test wheel.
Page 807 4 years, provided that they are kept out of direct sunlight, protected from the weather and humidity and stored in low oxygen conditions. If necessary, the Ferrari Service Network will verify whether old tyres are suitable for use. In all cases, tyres mounted on a vehicle for over 3 years must be inspected by an authorised Ferrari Service Centre.
Page 808 Tyres and rims Page 5 of 11 To more clearly identify the correct mounting positions for the tools relative to the wheel, the vertical column of the tyre demounting machine is used as the starting point (12 o'clock). Undo the core of the valve (A) to completely deflate the tyre.
Page 809 Tyres and rims Page 6 of 11 Observe the correct positions for bead breaking shown as follows. Position the inflation valve (A) at 12 o'clock. Position the bead breaker disc (3). Push the bead into the rim channel using the bead breaker disc while simultaneously turning the tyre counterclockwise, until the inflation valve (A) is at 3 o'clock.
Page 810 Tyres and rims Page 7 of 11 Ensure that the entire edge of the bead is outside the rim and completely visible. If this is not the case, the bead may be damaged. If the bead does not slide easily into the groove, lubricate the contact area.
Page 811 4 years, provided that they are kept out of direct sunlight, protected from the weather and humidity and stored in low oxygen conditions. If necessary, the Ferrari Service Network will verify whether old tyres are suitable for use. In all cases, tyres mounted on a vehicle for over 3 years must be inspected by an authorised Ferrari Service Centre.
Page 812 Tyres and rims Page 9 of 11 After installing the pressure sensor (A), mount the clean rim on the self-centring clamp, ensuring that the wheel is gripped correctly by the clamps (2) on the table. Lubricate the wheel. Pick up the tyre and ensure that the direction of rotation is correct.
Page 813 Tyres and rims Page 10 of 11 The bead breaker disc must never reach the valve-sensor assembly position. Fit the inflation valve (A) at 4-5 o'clock. Place the tyre on the rim, matching the lighter parts of the rim, marked with an embossed letter "G", with the yellow dots on the tyre.
Page 814 Tyres and rims Page 11 of 11 To ensure that the bead is mounted correctly, inflate the tyre immediately, while the beads are still lubricated. The tyre must be inflated to activate the tyre pressure monitoring system sensor. Inflate the tyre to a pressure greater than 0.6 bar and keep inflated at this pressure for a few minutes.
Page 815 Tyre pressure monitoring system Page 1 of 20 Print Exit D2.03 Tyre pressure monitoring system TPMS system layout A - Sensors B - Trigger C - Antenna D - Electronic control unit Operating the TPMS tyre pressure and temperature monitoring system The system must be calibrated from the relative menu option on the left hand TFT display after replacing or inflating any of the tyres.
Page 816 Tyre pressure monitoring system Page 2 of 20 These sensors transmit a signal received by the triggers fixed to the bodyshell behind the gravel guard, which are in turn connected to the ECU. The ECU processes the data received from the triggers and transmits the processed data to the instrument panel.
Page 817 Tyre pressure monitoring system Page 3 of 20 With any currently active screen, when the instrument panel receives the signal from the electronic control unit indicating that the pressure of a tyre is below the warning threshold, the TFT display displays the specific message “Check tyre pressure”...
Page 818 Tyre pressure monitoring system Page 4 of 20 TYRES screen: the driver may recall the screen by using the controls on the left hand TFT display, enabling identification of tyres with insufficient pressure at any time. When the system cannot recognise which wheel is generating the fault signal, as the respective values cannot be displayed by the TYRES screen, the screen is not recallable by the driver.
Page 819 Tyre pressure monitoring system Page 5 of 20 Upon selection of the menu option and subsequent successful calibration, the TFT display displays the specific message "Calibration activated" for 5 seconds. In “Calibration activated” state, the TYRES screen is recallable, but the pressure and temperature values are replaced by dashes.
Page 820 Tyre pressure monitoring system Page 6 of 20 - Punctured tyre When the instrument panel receives the signal from the electronic control unit indicating that the pressure of one or more normal tyres is below the alarm threshold, but the system cannot recognise which wheel is generating the fault signal, the TFT display displays the specific message “Low tyre pressure”...
Page 821 Tyre pressure monitoring system Page 7 of 20 When the instrument panel receives the signal from the electronic control unit indicating that the pressure of one or more RUN FLAT tyres is below the alarm threshold, but the system cannot recognise which wheel is generating the fault signal, the TFT display displays the specific message “Low tyre pressure”...
Page 822 Tyre pressure monitoring system Page 8 of 20 cancels the screen while leaving the relative warning light lit. TYRES screen: the screen may be recalled using the controls on the left hand TFT display, enabling the driver to identify punctured tyres at any time. When the system cannot recognise which wheel is generating the fault signal, as the respective values cannot be displayed by the TYRES screen, the screen is not recallable by the driver.
Page 823 Tyre pressure monitoring system Page 9 of 20 In the event of antenna reception disturbance caused by an RF source transmitting in the same frequency range as the sensors, or in the event of sensor overheat, or during calibration, or if the ECU does not recognise the sensor identifiers, the TFT display displays the specific message "TPMS temporarily inactive".
Page 824 Tyre pressure monitoring system Page 10 of 20 The TYRES screen is not recallable by the driver. Tyre pressure sensor The sensors are mounted to the wheel rim and secured by the inflation valve. The sensor must be correctly fixed to the valve for the system to function. ALWAYS replace with new components when REMOVING the TPMS sensor, complete with valve, from the rim.
Page 825 Tyre pressure monitoring system Page 11 of 20 Undo the nut (2) from the inflation valve, retrieving the insulator washer (3). Remove the sensor (6) with valve (4) from the wheel rim and replace. Refitting the tyre pressure sensor Tightening torque Class Fastening tyre inflation valve 4 Nm...
Page 826 Tyre pressure monitoring system Page 12 of 20 The sensor must not be treated with detergents, solvents or other harsh products. Do not clean with compressed air or pressurised liquids (e.g. pulivapor). Take particular care not to tear the surface of the filter interface (A) on the inner side of the sensor.
Page 827 Tyre pressure monitoring system Page 13 of 20 Use a rod to ensure that the hole on the valve is kept outside the rim. Fit the rod (1) in the radial hole of the valve and tighten the nut (2). ALWAYS use a torque wrench, using only certified and calibrated tools to ensure that the correct tightening torque is achieved.
Page 828 Tyre pressure monitoring system Page 14 of 20 Remove the rear element of the wheelhouse only. Disconnect the connector (1). Undo the indicated screws fastening the trigger (A) to the relevant mounting bracket. Remove the trigger (A) from the relevant mounting bracket and replace.
Page 829 Tyre pressure monitoring system Page 15 of 20 Disconnect the connector (1). Undo the indicated screws fastening the trigger (A) to the relevant mounting bracket. Remove the trigger (A) from the relevant mounting bracket and replace. Fit the new trigger (A) correctly on the relevant mounting bracket.
Page 830 Tyre pressure monitoring system Page 16 of 20 Located under the vehicle, covered by the centre flat undertray section. Disconnect the battery ( F2.01). Remove the central flat undertray section ( E3.12). Disconnect the connector (1). Undo the indicated screws; then remove and replace the antenna (A).
Page 831 Tyre pressure monitoring system Page 17 of 20 Undo the union (1). Open the indicated clamp on the pipe (2). Loosen the clamp (5). Disconnect the pipe (4) from the rigid pipe (3). Cut the clamp indicated by the red arrow. Undo the indicated screws and remove the bracket (6).
Page 832 Tyre pressure monitoring system Page 18 of 20 Disconnect the connector (12). Undo the indicated screws; then remove and replace the antenna (A). Fit the antenna (A) in the relative seat. Hand tighten the screws indicated. Connect the connector (12). Fit the AC system pipe (2).
Page 833 Tyre pressure monitoring system Page 19 of 20 Tighten the union (1). Tightening torque Class Union (FROM Ass.ly No. 26 Nm 90802) Close the indicated clamp on the pipe (2). Connect the pipe (4) to the rigid pipe (3). Tighten the clamp (5). Fit the lower part of the pillory block (7).
Page 834 Tyre pressure monitoring system Page 20 of 20 Fasten the brackets and the pillory blocks (11) onto the pipes (2) and (3), tightening the indicated screws. Tightening torque Class Screws (FROM Ass.ly No. 6 Nm 90802) Fill the cooling system ( A3.07).
Page 835 Brake system layout Page 1 of 1 Print Exit D3.01 Brake system layout Brake system layout A - Brake fluid tank B - Master brake cylinder C - Brake servo D - ABS/ASR electrohydraulic unit E - Brake callipers F - Brake pads G - Brake discs H - Yaw sensor...
Page 836 Brake fluid tank Page 1 of 3 Print Exit D3.02 Brake fluid tank Removing the brake fluid tank The fluid contained in the brake system is harmful in the event of contact with the eyes or skin. In the event of contact with brake fluid, rinse the affected area immediately with plenty of running water. Brake fluid may also damage paintwork.
Page 837 Brake fluid tank Page 2 of 3 Undo the two nuts indicated fastening the brake fluid reservoir (A) to the chassis. Remove the brake fluid reservoir (A) from the relative seat. Refitting the brake fluid tank Tightening torque Class Fastening brake fluid reservoir 9 Nm The fluid contained in the brake system is harmful in the event of contact with the eyes...
Page 838 Brake fluid tank Page 3 of 3 Remove the relative caps, connect the two pipes (2) to the brake fluid reservoir (A) and tighten the relative metal fastener clamps. Connect the brake fluid level sensor connector (1) to the brake fluid reservoir (A). Reconnect the battery ( F2.01).
Page 839 Brake discs Page 1 of 2 Print Exit D3.03 Brake discs Removing the brake discs Remove the wheels ( D2.01). Remove the rear brake callipers ( D3.05). Applicable only for removing the rear discs. DO NOT disconnect the calliper fluid pipe and take particular care not to damage the pipe when handling the calliper.
Page 840 Brake discs Page 2 of 2 Fit the disc on the wheel bearing. To centre the disc on the wheel bearing, hand tighten the wheel fastener stud bolts into their seats. Tighten the screw (2) fastening the disc. Tightening torque Class Screw 15.5 Nm...
Page 841 Brake pads Page 1 of 5 Print Exit D3.04 Brake pads Removing the front brake pads Disconnect the battery ( F2.01). Remove the wheels ( D2.01). Remove the front wheels only. Disconnect connector (1) of brake pad wear sensor, and detach it from the relative mounting bracket. Remove the indicated cable ties.
Page 842 Brake pads Page 2 of 5 Tightening torque Class Fastening central pin on front brake pads Screw 27 ÷ 33 Nm Further separate the calliper pistons with the tool (FACOM DF.6). Fit the brake pads (A) in the relative seats. Install the pin (6).
Page 843 Brake pads Page 3 of 5 Remove the rear wheels. Disconnect the connector (1) for the brake pad wear sensor. Cut the indicated clamps and remove the brake pad wear sensor cable from the retainers (2). Remove the pin (4), tapping with a suitable punch and mallet.
Page 844 Brake pads Page 4 of 5 Fit the pads (A). Install the pin (6), tapping with a suitable punch and mallet. Fit the spring (5). Install the pin (4), tapping with a suitable punch and mallet. Fit new clamps as indicated to fasten the brake pad wear sensor cable and fit the cable in the retainers (2).
Page 845 Brake pads Page 5 of 5 Brake 16 times from 80 Km/h to 20 Km/h with constant pressure on the brake pedal and without activating the ABS system. Leave the brake system to cool for approximately 120 seconds. Brake 16 times from 120 Km/h to 20 Km/h with constant pressure on the brake pedal and without activating the ABS system.
Page 846 Brake callipers Page 1 of 3 Print Exit D3.05 Brake callipers Removing the front brake callipers The fluid contained in the brake system is harmful in the event of contact with the eyes or skin. In the event of contact with brake fluid, rinse the affected area immediately with plenty of running water. Brake fluid may also damage paintwork.
Page 847 Brake callipers Page 2 of 3 Check that the calliper mating surfaces with the stub axle are clean, fit the brake calliper (A) to the disc and hand tighten the two screws (2). Tightening torque Class Screw 100 Nm Fit the rigid pipe on the brake calliper, tightening the union (1).
Page 848 Brake callipers Page 3 of 3 Tightening torque Class Fastening brake calliper to hub carrier Screw 100 Nm Fastening brake fluid hose to rear brake calliper Union 21.5 Nm Check that the calliper mating surfaces with the stub axle are clean, fit the calliper (A) to the disc and tighten the two screws (2).
Page 849 ABS/ASR electrohydraulic unit Page 1 of 4 Print Exit D3.06 ABS/ASR electrohydraulic unit Replacing the ABS/ASR electrohydraulic unit Tightening torque Class Fastening electrohydraulic ABS/ASR unit to Screw 18 Nm mounting bracket Fastening electrohydraulic ABS/ASR unit Screw 24 Nm mounting bracket to chassis Fastening brake fluid pipe on the electrohydraulic M10 - M12 union 16 Nm...
Page 850 ABS/ASR electrohydraulic unit Page 2 of 4 Detach the brake fluid pipes, removing the indicated clips. Detach the brake fluid pipes, removing the indicated clips. Disconnect the connector (2). Take note of the pipes' position on the electrohydraulic ABS/ASR unit (3) so as to refit them correctly afterwards.
Page 851 ABS/ASR electrohydraulic unit Page 3 of 4 On the workbench separate the electrohydraulic ABS/ASR unit (3) from the relevant mounting bracket, undoing the indicated screws. Check the state of the mounting bushings; replace if necessary. Refit the electrohydraulic ABS/ASR unit (3) on the relevant mounting bracket, tightening the indicated screws.
Page 852 ABS/ASR electrohydraulic unit Page 4 of 4 Fasten the brake fluid pipes by placing the indicated clips. Fasten the brake fluid pipes by placing the indicated clips. Fit and fasten the air duct (1) by tightening the screws indicated. Tightening torque Class Screw 1.5 Nm...
Page 853 EPB electric parking brake Page 1 of 17 Print Exit D3.07 EPB electric parking brake the parking brake is engaged and released with the specific control on the dashboard, to the left of the steering wheel; the brake is actuated by an electric motor; the brake engages automatically when the engine is switched off (Autohold function);...
Page 854 EPB electric parking brake Page 2 of 17 A - ECU B - Equaliser bracket C - Bowden cables D - Shoes Disabling the EPB electric parking brake Autohold function The EPB electric parking brake is engaged automatically at each Key-off, as the Autohold function is always enabled by default.
Page 855 EPB electric parking brake Page 3 of 17 Press the AUTO PARK button (B). Wait for the specific message "PARK OFF" to appear on the TFT display. Turn the ignition key to 0 (Key-OFF). Emergency EPB electric parking brake release procedure CAUTION When the electric parking brake is deactivated manually, the vehicle may move unexpectedly! The vehicle is held in position only by the Park Lock safety device, if engaged.
Page 856 For safety reasons, it is IMPERATIVE that the following indications are followed correctly. The parking brake will return to normal functionality, however, the vehicle must still be taken to a Ferrari service centre to calibrate the system and delete any errors from the failure memory. The system must be calibrated for safety reasons.
Page 857 EPB electric parking brake Page 5 of 17 Disable the EPB electric parking brake Autohold function ( D3.07). Remove the wheels ( D2.01). Remove the rear ones. Remove the brake discs ( D3.03). Remove the rear ones. Remove the rear bumper ( E3.04).
Page 858 EPB electric parking brake Page 6 of 17 Detach the cable grommet (4) from the bracket on the right hand EPB Bowden cable sheath (B). Undo the nut (5) fastening the ground cable onto the bracket on the right hand EPB Bowden cable sheath (B).
Page 859 EPB electric parking brake Page 7 of 17 Release the spring (12) and remove the brake shoes (E), taking care not to shift the linkage pins (13). Refitting the EPB electric parking brake shoes Tightening torque Class Fastening EPB Bowden cable - rear hub carrier Screw 8 Nm Fastening brake pad sensor ground cable...
Page 860 EPB electric parking brake Page 8 of 17 Fit the lower spring (11) in the respective seat, pushing towards the brake shoes and then turning the spring. Fit the upper spring (10) in the respective seat, pushing towards the brake shoes and then turning the spring.
Page 861 EPB electric parking brake Page 9 of 17 Tighten the indicated screw fastening the right hand EPB Bowden cable sheath (B) onto the rear right hand hub carrier. Tightening torque Class Screw 8 Nm Tighten the nut (5) fastening the ground cable onto the bracket on the right hand EPB Bowden cable sheath (B).
Page 862 EPB electric parking brake Page 10 of 17 Press on the two indicated fastener tabs and fit the left hand EPB Bowden cable sheath (D) into the relevant mounting bracket. Attach the end (2) of the left hand EPB Bowden cable (D) to the EPB linkage bracket (A).
Page 863 EPB electric parking brake Page 11 of 17 Left hand EPB Bowden cable Use a suitable screwdriver to prise the clip (1) off the EPB linkage bracket (A). Detach the end (2) of the left hand EPB Bowden cable (D) from the EPB linkage bracket (A). Press on the two indicated fastener tabs and remove the left hand EPB Bowden cable sheath (D) from the relative mounting bracket.
Page 864 EPB electric parking brake Page 12 of 17 Detach the cable grommet (4) from the bracket. Undo the nut (6) fastening the ground cable. Undo the indicated screw fastening the left hand EPB Bowden cable sheath (D) onto the hub carrier.
Page 865 EPB electric parking brake Page 13 of 17 Fasten the indicated clamp retaining the left hand EPB Bowden cable (D). Fasten the indicated clamp retaining the left hand EPB Bowden cable (D). Press on the two indicated fastener tabs and fit the left hand EPB Bowden cable sheath (D) into the relative mounting bracket.
Page 866 EPB electric parking brake Page 14 of 17 Remove the safety pin (14). Detach the end (3) of the right hand EPB Bowden cable (B) from the EPB equaliser (C). Press on the two indicated fastener tabs and remove the right hand EPB Bowden cable sheath (B) from the relative mounting bracket.
Page 867 EPB electric parking brake Page 15 of 17 Detach the cable grommet (4) from the bracket. Undo the nut (6) fastening the ground cable. Undo the indicated screw fastening the right hand EPB Bowden cable sheath (B) onto the hub carrier.
Page 868 EPB electric parking brake Page 16 of 17 Fasten the indicated clamp retaining the right hand EPB Bowden cable (B). Fasten the right hand EPB Bowden cable (B) by tightening the stud bolt (17). Tighten the indicated screw fastening the EPB control unit Bowden cable.
Page 869 EPB electric parking brake Page 17 of 17 Adjusting the EPB electric parking brake After replacing the EPB brake shoes, the parking brake must be adjusted correctly with the following procedure. Insert a suitably sized screwdriver into the slot (A) on the rear disc.
Page 870 Brake servo - Pump Page 1 of 4 Print Exit D3.08 Brake servo - Pump Removing the brake servo Remove the windscreen wiper linkage ( E3.09). Remove the antitheft system siren ( F4.01). Open the indicated retainer on the pipes (1). Undo the screws indicated.
Page 871 Brake servo - Pump Page 2 of 4 Some brake fluid may leak when detaching the unions from the master brake cylinder; ensure that the oil does not come into contact with surrounding parts. The fluid contained in the brake system is harmful in the event of contact with the eyes or skin.
Page 872 Brake servo - Pump Page 3 of 4 Ensure that the retainer clip (5) is installed correctly on the brake servo. Working from the luggage compartment, fit the brake servo (A), complete with pump, in the relative seat on the firewall. Working from underneath the driver side of the dashboard, align the linkage (6) in the relative seat on the brake servo (A).
Page 873 Brake servo - Pump Page 4 of 4 Fit the complete TGK valves (2) in the relative seat. Hand tighten the screws indicated. Tightening torque Class Screw 8 Nm Fasten the rigid pipes (1) by closing the indicated clamp. Refit the antitheft system siren ( F4.01).
Page 874 Pedal board Page 1 of 5 Print Exit D3.09 Pedal board Removing the pedal board Disconnect the battery ( F2.01). Remove the complete dashboard ( E4.02). Working from underneath the driver side of the dashboard, detach the brake servo linkage (6), removing the retainer clip (5).
Page 875 Pedal board Page 2 of 5 Tightening torque Class Fastening brake servo - pedal board 20 Nm Fastening pedal board to firewall Screw 20 Nm Fit the pedal board (B) in the relative seat in the passenger compartment, hand-tightening all the indicated fasteners.
Page 876 Pedal board Page 3 of 5 Tightening torque Class Screw 8.5 Nm In some of the following photographs, the dashboard has been removed from the passenger compartment to illustrate the procedure more clearly. Disconnect the battery ( F2.01). Remove the mats ( E4.05).
Page 877 Pedal board Page 4 of 5 Extend the pin (3) on the new switch completely. New switches are supplied with the pin in an intermediate position and not fully extended. Keep the brake pedal depressed. Fit the new switch (A) fully into the relative seat. Note that the mounting shown in the photo aside is an example only and is not the specific part for the vehicle.
Page 878 Pedal board Page 5 of 5 Place a 1 mm thick shim (4) between the brake pedal (5) and the pin on the switch (A). Release the brake pedal so that it presses against the pin on the switch, allowing the pin to self- adjust.
Page 879 Filling and bleeding the brake system Page 1 of 3 Print Exit D3.10 Filling and bleeding the brake system Filling and bleeding the brake system Tightening torque Class Fastening bleed unions - brake callipers Union 17 ÷ 20 Nm Remove the wheels ( D2.01).
Page 880 Filling and bleeding the brake system Page 2 of 3 Always use fresh oil of the recommended type and in the quantity indicated, taken from sealed containers. The circuit is filled with synthetic oil. Using mineral oil may cause irreparable damage to the rubber seals in the system.
Page 881 Filling and bleeding the brake system Page 3 of 3 Always use fresh oil of the recommended type and in the quantity indicated, taken from sealed containers. The circuit is filled with synthetic oil. Using mineral oil may cause irreparable damage to the rubber seals in the system.
Page 882 Complete suspension Page 1 of 25 Print Exit D4.01 Complete suspension Removing complete front suspension The following procedure is for the removal of the right hand front suspension. The procedure for removing the left hand front suspension is the same. Note that in some of the following images the vehicle is shown with the wheelhouse and the front flat undertray section removed.
Page 883 Complete suspension Page 2 of 25 Disconnect the connector (3) from the shock absorber. Disconnect connector (4) of ABS sensor, and detach it from the relevant mounting bracket. Disconnect connector (5) of brake pad wear sensor, and detach it from the relevant mounting bracket. Detach the cable grommet (6) from the relevant mounting bracket.
Page 884 Complete suspension Page 3 of 25 Undo the brake fluid hose union (10). Remove the clip (11) fastening the union (12) for the brake fluid hose onto the relative mounting bracket. Remove the union (12) for the brake fluid hose from the relative mounting bracket.
Page 885 (even if only on one threaded rod), a ROL (Red On Line) must be opened, attaching adequate photographic documentation, and contact the Ferrari Help Desk. If the markings on the threaded rods and eyebolts are correctly aligned after loosening the arm...
Page 886 Complete suspension Page 5 of 25 Support the weight of the suspension adequately. DO NOT use lubricants or electric/pneumatic drivers. Undo the two screws fastening the shock absorber (D) to the chassis. Using a delible yellow marker pen or paint, make reference markings on the threaded rods and relative nuts and the eyebolts of the Flanblocs fastening the upper arm.
Page 887 (even if only on one threaded rod), a ROL (Red On Line) must be opened, attaching adequate photographic documentation, and contact the Ferrari Help Desk. If the markings on the threaded rods and eyebolts are correctly aligned after loosening the arm...
Page 888 Complete suspension Page 7 of 25 Tightening torque Class Fastening brake pipe union or connection M10 union 16 Nm Fastening front stabiliser bar to tie-rod 50 Nm Fastening steering box tie-rod to hub carrier 40 Nm The following procedure is for refitting of right hand front suspension. The procedure for refitting the left hand front suspension is the same.
Page 889 Complete suspension Page 8 of 25 Check that the yellow reference markings are correctly aligned: the markings on the threaded rods and the markings on the Flanbloc eyebolts must be aligned. Remove the yellow reference markings made during removal. Using an indelible red marker pen or paint, make reference markings on the threaded rods and relative nuts and the eyebolts of the Flanblocs fastening the upper arm.
Page 890 Complete suspension Page 9 of 25 Fit the four shims (8) in the relevant seats, pushing down completely onto the threaded rods and ensuring that they are perfectly perpendicular to the horizontal axis of the Flanblocs. Clean the mating surfaces with a degreasing product (heptane).
Page 891 Complete suspension Page 10 of 25 Remove the yellow reference markings made during removal. Using an indelible red marker pen or paint, make reference markings on the threaded rods and relative nuts and the eyebolts of the Flanblocs fastening the lower arm. Tighten the nut (7) fastening the ground cable.
Page 892 Complete suspension Page 11 of 25 Fit the union (12) for the brake fluid hose onto the relevant mounting bracket. Refit the clip (11) fastening the union (12) for the brake fluid hose onto the relative mounting bracket. Tighten the brake fluid hose union (10). Tightening torque Class M10 union...
Page 893 Complete suspension Page 12 of 25 Tighten the nut (2) fastening the stabiliser bar (B). Tightening torque Class 50 Nm Pre-tighten the nut (1) fastening the steering box tie- rod (A). Tightening torque Class 40 Nm Loosen the nut (1) then tighten again. Tightening torque Class 40 Nm...
Page 894 Complete suspension Page 13 of 25 Remove the rear element of the rear wheelhouse. Detach the tie-rod (1) for the NRRPS motion sensor from the lower arm. Disconnect the connector (2) for the brake pad wear sensor. Disconnect the connector (3) for the ABS sensor. Detach the cable grommet (4) from the relevant mounting bracket.
Page 895 Complete suspension Page 14 of 25 Undo the six screws (12) fastening the axle shaft (A) to the differential flange and retrieve the three spacers (13). Disconnect the connector (14) from the shock absorber (B). Support the weight of the complete suspension adequately.
Page 896 (even if only on one threaded rod), a ROL (Red On Line) must be opened, attaching adequate photographic documentation, and contact the Ferrari Help Desk. If the markings on the threaded rods and eyebolts are correctly aligned after loosening the toe-in tie-...
Page 897 Complete suspension Page 16 of 25 Using a delible yellow marker pen or paint, make reference markings on the threaded rods and relative nuts and the eyebolts of the Flanblocs fastening the upper arm. Undo the nut indicated fastening the stabiliser bar (D) to the spherical tie-rod.
Page 898 (even if only on one threaded rod), a ROL (Red On Line) must be opened, attaching adequate photographic documentation, and contact the Ferrari Help Desk. If the markings on the threaded rods and Flanbloc eyebolts are correctly aligned after loosening the...
Page 899 (even if only on one threaded rod), a ROL (Red On Line) must be opened, attaching adequate photographic documentation, and contact the Ferrari Help Desk. If the markings on the threaded rods and Flanbloc eyebolts are correctly aligned after loosening the...
Page 900 Complete suspension Page 19 of 25 Refitting complete rear suspension Tightening torque Class Fastening lower arm to chassis Nut (pretightening) 9 Nm 60 Nm Fastening upper arm to chassis Nut (pretightening) 9 Nm 60 Nm Fastening rear stabiliser bar to tie-rod 50 Nm Fastening toe-in tie-rod to chassis Nut (pretightening)
Page 901 Complete suspension Page 20 of 25 Fit the four shims (16) in the relevant seats, pushing down completely onto the threaded rods and ensuring that they are perfectly perpendicular to the horizontal axis of the Flanblocs. Clean the mating surfaces with a degreasing product (heptane).
Page 902 Complete suspension Page 21 of 25 Remove the yellow reference markings made during removal. Using an indelible red marker pen or paint, make reference markings on the threaded rods and relative nuts and the eyebolts of the Flanblocs fastening the lower arm. Clean the mating surfaces with a degreasing product (heptane).
Page 903 Complete suspension Page 22 of 25 Remove the yellow reference markings made during removal. Using an indelible red marker pen or paint, make reference markings on the threaded rods and relative nuts and the eyebolts of the Flanblocs fastening the upper arm. Tighten the nut indicated fastening the stabiliser bar (D) to the spherical tie-rod.
Page 904 Complete suspension Page 23 of 25 Check that the yellow reference markings are correctly aligned: the markings on the threaded rods and the markings on the eyebolts must be aligned. Remove the yellow reference markings made during removal. Using an indelible red marker pen or paint, make reference markings on the threaded rods and the relative nuts and eyebolts fastening the toe-in tie- rod.
Page 905 Complete suspension Page 24 of 25 Refit the three spacers (13) and tighten the six screws (12) fastening the axle shaft (A) to the differential flange. Tightening torque Class Screw 78 Nm Insert the brake fluid hose (11) into the relevant mounting bracket.
Page 906 Complete suspension Page 25 of 25 Tighten the indicated screw fastening the EPB Bowden cable sheath (8). Tightening torque Class Screw 8 Nm Tighten the nut (7) fastening the ground cable onto the bracket on the EPB Bowden cable sheath (8). Tightening torque Class 6 Nm...
Page 907 Suspension arms Page 1 of 24 Print Exit D4.02 Suspension arms Removing front suspension upper arms The replacement arm is supplied complete with Flanbloc and ball joint. The following procedure is for removing the right hand front suspension upper arm. The procedure for removing the left hand front suspension upper arm is the same.
Page 908 (even if only on one stud bolt), a ROL (Red On Line) must be opened, attaching adequate photographic documentation, and contact the Ferrari Help Desk. If the markings on the stud bolts and eyebolts are correctly aligned after loosening the arm fastener...
Page 909 Suspension arms Page 3 of 24 Check again that the yellow reference markings are correctly aligned: the markings on the stud bolts and the markings on the Flanbloc eyebolts must be aligned. Undo the nut (3) fastening the upper arm (B) to the hub carrier (C), retrieving the relevant washer.
Page 910 Suspension arms Page 4 of 24 Position the four washers onto the relative stud bolts and upper lever (B) of front suspension into the relative seats. Hand tighten the nut (3), fitting the relevant washer, fastening the upper arm (B) to the hub carrier (C) and pretighten.
Page 911 Suspension arms Page 5 of 24 Check that the yellow reference markings are correctly aligned: the markings on the stud bolts and the markings on the Flanbloc eyebolts must be aligned. Remove the yellow reference markings made during removal. Using an indelible red marker pen or paint, make reference markings on the stud bolts and relative nuts and the eyebolts of the Flanblocs fastening the upper arm.
Page 912 Suspension arms Page 6 of 24 Connect the connector (1) to the shock absorber. Refit the wheels ( D2.01). Reconnect the battery ( F2.01). Refit the luggage compartment cosmetic shields ( E4.07). Perform the vehicle set-up procedure ( A3.22). Removing front suspension lower arms The replacement arm is supplied complete with Flanbloc and ball joint.
Page 913 (even if only on one stud bolt), a ROL (Red On Line) must be opened, attaching adequate photographic documentation, and contact the Ferrari Help Desk. If the markings on the stud bolts and eyebolts are correctly aligned after loosening the arm fastener...
Page 914 Suspension arms Page 8 of 24 Check again that the yellow reference markings are correctly aligned: the markings on the stud bolts and the markings on the Flanbloc eyebolts must be aligned. Remove the lower front suspension arm from its relevant seat. Refitting front suspension lower arms Tightening torque Class...
Page 915 Suspension arms Page 9 of 24 Fit the lower front suspension arm (A) in its relevant seat. Apply the nut (4), after fitting the relevant washer, and pretighten. Tightening torque Class Nut (pretightening) 90 Nm Loosen the nut (4) and then tighten. Tightening torque Class 63 Nm...
Page 916 Suspension arms Page 10 of 24 Fit the four shims (5) in the relevant seats, pushing down completely onto the stud bolts and ensuring that they are perfectly perpendicular to the horizontal axis of the Flanblocs. Clean the mating surfaces with a degreasing product (heptane).
Page 917 Suspension arms Page 11 of 24 Remove the yellow reference markings made during removal. Using an indelible red marker pen or paint, make reference markings on the stud bolts and relevant nuts and the eyebolts of the Flanblocs fastening the lower arm. Refit the wheels ( D2.01).
Page 918 (even if only on one stud bolt), a ROL (Red On Line) must be opened, attaching adequate photographic documentation, and contact the Ferrari Help Desk. If the markings on the stud bolts and Flanbloc eyebolts are correctly aligned after loosening the...
Page 919 Suspension arms Page 13 of 24 Refitting rear suspension upper arms Tightening torque Class Fastening upper arm to hub carrier 90 Nm Fastening upper arm to chassis Nut (pretightening) 9 Nm 60 Nm The replacement arm is supplied complete with Flanbloc. The following procedure is for refitting the right hand rear suspension upper arm.
Page 920 Suspension arms Page 14 of 24 Check that the yellow reference markings are correctly aligned: the markings on the stud bolts and the markings on the Flanbloc eyebolts must be aligned. Remove the yellow reference markings made during removal. Using an indelible red marker pen or paint, make reference markings on the stud bolts and relative nuts and the eyebolts of the Flanblocs fastening the upper arm.
Page 921 Suspension arms Page 15 of 24 Detach and remove the rubber plug (C) from the front of the lower arm. Detach and remove the rubber plug (D) from the rear of the lower arm. Holding the pin (5) fastening the shock absorber to the lower arm still, undo the nut (6) and retrieve the relevant washer.
Page 922 Suspension arms Page 16 of 24 Detach the tie-rod (1) for the NRRPS motion sensor from the lower arm (A). Magnetorheological shock absorbers (optional) only. Undo the nut (2) and remove the screw (3), retrieving the relevant washer. Using a delible yellow marker pen or paint, make reference markings on the stud bolts and relative nuts and the eyebolts of the Flanblocs fastening the lower arm.
Page 923 (even if only on one stud bolt), a ROL (Red On Line) must be opened, attaching adequate photographic documentation, and contact the Ferrari Help Desk. If the markings on the stud bolts and Flanbloc eyebolts are correctly aligned after loosening the...
Page 924 Suspension arms Page 18 of 24 The following procedure is for refitting the right hand rear suspension lower arm. The procedure for refitting the left hand rear suspension lower arm is the same. Support the weight of the rear suspension adequately. Fit the rear suspension lower arm (A) in its relevant seat.
Page 925 Suspension arms Page 19 of 24 Check that the yellow reference markings are correctly aligned: the markings on the stud bolts and the markings on the Flanbloc eyebolts must be aligned. Remove the yellow reference markings made during removal. Using an indelible red marker pen or paint, make reference markings on the stud bolts and relative nuts and the eyebolts of the Flanblocs fastening the lower arm.
Page 926 Suspension arms Page 20 of 24 Fit the pin (5) in the relevant seat. Holding the pin (5) still, fit the relevant washer and tighten the nut (6) fastening the shock absorber to the lower arm. Tightening torque Class Screw 80 Nm Press the rubber plug (D) by hand into its relevant seat at the rear of the lower arm.
Page 927 Suspension arms Page 21 of 24 Remove the wheels ( D2.01). Using a delible yellow marker pen or paint, make reference markings on the threaded bolts and relative nuts and the eyebolts fastening the toe- in tie-rod. Holding the pin (1) still, undo the nut (2) and retrieve the relevant washers.
Page 928 (even if only on one threaded rod), a ROL (Red On Line) must be opened, attaching adequate photographic documentation, and contact the Ferrari Help Desk. If the markings on the threaded rods and eyebolts are correctly aligned after loosening the toe-in tie- rod fastener nuts, completely undo and remove the two toe-in tie-rod fastener nuts.
Page 929 Suspension arms Page 23 of 24 Fit the relative washers and tighten the nut (2), holding the pin (1) still to prevent it from turning. Tightening torque Class 80 Nm Clean the mating surfaces with a degreasing product (heptane). DO NOT use lubricants or electric/pneumatic drivers.
Page 930 Suspension arms Page 24 of 24 Remove the yellow reference markings made during removal. Using an indelible red marker pen or paint, make reference markings on the threaded rods and the relative nuts and eyebolts fastening the toe-in tie- rod. Refit the wheels ( D2.01).
Page 931 Hub carriers Page 1 of 11 Print Exit D4.03 Hub carriers Removing the front hub carriers Remove the front brake callipers ( D3.05). Remove the brake discs ( D3.03). Remove the front disc. Remove the indicated cable ties. Disconnect ground cable from the indicated clip. Release and disconnect connector (1).
Page 932 Hub carriers Page 2 of 11 Undo the nut (9), retrieving the relative washer. Detach the hub carrier (A) from the steering box tie- rod (B). Undo the nut (10), retrieving the relative washer. Detach the hub carrier (A) from the upper arm (C). Undo the nut (11), retrieving the relative washer.
Page 933 Hub carriers Page 3 of 11 Remove the hub carrier (A). Undo the screws (12). Remove the bracket (13). Undo the screws (14). Remove the brake disc shield (15). Refitting the front hub carriers Tightening torque Class Brake disc shield bracket Screw 9 ÷...
Page 934 Hub carriers Page 4 of 11 Fit the brake disc shield (15). Tighten the screws (14). Tightening torque Class Screw 9 ÷ 12 Nm Fit the bracket (13). Tighten the screws (12). Tightening torque Class Screw 9 ÷ 12 Nm Fit the hub carrier (A).
Page 935 Hub carriers Page 5 of 11 Attach the hub carrier (A) to the upper arm (C). Clean the ball joint head and the relative seat thoroughly. Fit the relative washer and pre-tighten the nut (10). Tightening torque Class 52 Nm Loosen and tighten the nut (10).
Page 936 Hub carriers Page 6 of 11 Attach the pipe (7) to the clip (8). Tighten the union (6). Tightening torque Class M10 union 16 Nm Fit the clip (5). Attach the cable grommets (4). Tighten the nut (3). Tightening torque Class 6 Nm Attach the cable grommet (2).
Page 937 Hub carriers Page 7 of 11 Preventing the screw (1) fastening the lower arm (A) to the hub carrier from turning, undo the nut (2). Remove the screw (1) from the relative seat and retrieve the relative washers. Preventing the screw (3) fastening the toe-in tie-rod (B) to the hub carrier from turning, undo the nut (4).
Page 938 Hub carriers Page 8 of 11 Preventing the screw (5) fastening the upper arm (C) to the hub carrier from turning, undo the nut (6). Remove the screw (5) from the relative seat and retrieve the relative washers. Undo the three screws indicated fastening the brake disc shield (D) to the hub carrier (E).
Page 939 Hub carriers Page 9 of 11 Apply three even and regularly spaced circular beads of AREXONS SYSTEM 56A01 - HIGH STRENGTH RETAINING COMPOUND. Support the weight of the suspension adequately. Fit the hub carrier (E), fitting the axle shaft into the relative seat on the wheel bearing.
Page 940 Hub carriers Page 10 of 11 Fit the screw (5) in the relative seat after installing the relative washer. Fit the relative washer and, preventing the screw (5) fastening the upper arm (C) to the hub carrier from turning, tighten the nut (6). Tightening torque Class 90 Nm...
Page 941 Hub carriers Page 11 of 11 Fit the screw (1) in the relative seat after installing the relative washer. Fit the relative washer and, preventing the screw (1) fastening the lower arm (A) to the hub carrier from turning, tighten the nut (2). Tightening torque Class 205 Nm...
Page 942 Shock absorbers Page 1 of 16 Print Exit D4.04 Shock absorbers Removing the front shock absorber The following procedure is for removing the right hand front shock absorber. The procedure for removing the left hand front shock absorber is the same. Remove the luggage compartment cosmetic shields ( E4.07).
Page 943 Shock absorbers Page 2 of 16 Using a delible yellow marker pen or paint, make reference markings on the stud bolts and relative nuts and the eyebolts of the Flanblocs fastening the upper arm. Detach the tie-rod for the NRRPS motion sensor (2) from the upper arm (B).
Page 944 (even if only on one stud bolt), a ROL (Red On Line) must be opened, attaching adequate photographic documentation, and contact the Ferrari Help Desk. If the markings on the stud bolts and eyebolts are correctly aligned after loosening the arm fastener...
Page 945 Shock absorbers Page 4 of 16 Refitting the front shock absorber Tightening torque Class Fastening shock absorber to lower arm Screw 80 Nm Fastening vehicle lift system unions Union 16 Nm Fastening upper arm to chassis Nut (pretightening) 9 Nm 60 Nm Fastening shock absorber to chassis Screw...
Page 946 Shock absorbers Page 5 of 16 Clean the mating surfaces with a degreasing product (heptane). DO NOT use lubricants or electric/pneumatic drivers. ALWAYS replace the suspension arm fastener nuts, complete with relative washers, each time they are removed. Replacement is NOT necessary if the nuts are loosened only.
Page 947 Shock absorbers Page 6 of 16 Check that the yellow reference markings are correctly aligned: the markings on the stud bolts and the markings on the Flanbloc eyebolts must be aligned. Remove the yellow reference markings made during removal. Using an indelible red marker pen or paint, make reference markings on the stud bolts and relative nuts and the eyebolts of the Flanblocs fastening the upper arm.
Page 948 Shock absorbers Page 7 of 16 Removing the rear shock absorber The following procedure is for removing the right hand rear shock absorber. The procedure for removing the left hand rear shock absorber is identical. Remove the wheels ( D2.01). Disconnect the battery ( F2.01).
Page 949 Shock absorbers Page 8 of 16 Detach and remove the rubber plug (D) from the rear of the lower arm. Holding the pin (5) fastening the shock absorber to the lower arm still, undo the nut (6) and retrieve the relevant washer. Support the weight of the shock absorber (A) and remove the pin (5) from the relevant seat.
Page 950 Shock absorbers Page 9 of 16 Fit the pin (5) in the relevant seat. Holding the pin (5) still, fit the relevant washer and tighten the nut (6) fastening the shock absorber to the lower arm. Tightening torque Class Screw 80 Nm Press the rubber plug (D) by hand into its relevant seat at the rear of the lower arm.
Page 951 Shock absorbers Page 10 of 16 Tighten the two screws indicated fastening the shock absorber (A) to the chassis. Tightening torque Class Screw 110 Nm Connect the connector (1) to the shock absorber (A). Reconnect the battery ( F2.01). Refit the wheels ( D2.01).
Page 952 Shock absorbers Page 11 of 16 Detach and remove the connector (1). Immobilise the shock absorber. Undo the nut (2). CAUTION The following procedure for removing the nut must be observed precisely in order to compress and remove the spring safely. Partially loosen the nut (3) by just enough to decompress the spring.
Page 953 Shock absorbers Page 12 of 16 Detach and remove the connector (1). Immobilise the shock absorber. Undo the nut (2). CAUTION The following procedure for removing the nut must be observed precisely in order to compress and remove the spring safely. Partially loosen the nut (3) by just enough to decompress the spring.
Page 954 Shock absorbers Page 13 of 16 Apply grease Z2 PROTECTION to the surface of the lower shim (E) in contact with the spring (A). Fit the lower shim (E) on the shock absorber. Fit the plug (D). Fit the spring (A). Apply grease Z2 PROTECTION to the surface of the upper shim (C) in contact with the spring (A).
Page 955 Shock absorbers Page 14 of 16 Fit the shim ring (G). Apply grease Z2 PROTECTION to the surfaces of the shock absorber and shim ring (G) in contact with the actuator (F). Fit the actuator (F). With the shock absorber oriented as it would be in the vehicle, the actuator bleed valve (F) must be turned by 37°...
Page 956 Shock absorbers Page 15 of 16 Adjusting the shock absorber length The distance (L) from the disc to the lower fulcrum axis must be adjusted in accordance with the spring fitted and the type of shock absorber on which it is fitted. Two different spring sizes are available with different control load tolerances, identifiable by the different colours stamped on a coil turn.
Page 957 Shock absorbers Page 16 of 16 Tightening torque Class Shock absorber ring nut Ring nut 65 Nm Using a standard pin wrench, loosen the ring nut (A) fastening the stop cap. Hand tighten or loosen the spring retainer stop cap (B) to obtain the distance (L).
Page 958 Stabiliser bars - Tie-rods Page 1 of 10 Print Exit D4.05 Stabiliser bars - Tie-rods Removing the rear stabiliser bar Remove the rear wheelhouses ( E3.05). Remove the rear elements of the rear wheelhouses only. Remove the engine air filter box ( B4.03).
Page 959 Stabiliser bars - Tie-rods Page 2 of 10 Tightening torque Class Fastening rear stabiliser bar to chassis Screw 60 Nm Products to use: AREXONS SYSTEM 52A43 - MEDIUM STRENGTH THREAD LOCK Fastening rear stabiliser bar to tie-rod 50 Nm Apply 1 ml of DuPont Lubricants Krytox® 205 GPL Standard Grade Grease grease in a uniform film over the entire inner surface and on the lateral surfaces (contact surfaces only) of the...
Page 960 Stabiliser bars - Tie-rods Page 3 of 10 Fit the retainer plate on the bushing and fasten the rear stabiliser bar (A), tightening the screws indicated. Tightening torque Class Screw 60 Nm Fasten the rear stabiliser bar (A) to the tie-rod, tightening the nut (2).
Page 961 Stabiliser bars - Tie-rods Page 4 of 10 Tightening torque Class Spherical tie-rod - lower arm Spherical tie-rod 50 Nm Fastening rear stabiliser bar to tie-rod 50 Nm Remove the rear wheelhouses ( E3.05). Remove the rear element of the rear wheelhouse. Undo the nut (1), retrieving the relevant washer.
Page 962 Stabiliser bars - Tie-rods Page 5 of 10 Tighten the nut (1) fitting the relevant washer. Tightening torque Class 50 Nm Refit the rear wheelhouses ( E3.05). Removing the front stabiliser bar Remove the wheels ( D2.01). Remove the front wheels. Undo the nut (1) fastening the stabiliser bar (A) to the spherical tie-rod (2).
Page 963 Stabiliser bars - Tie-rods Page 6 of 10 Undo the nut (3) fastening the stabiliser bar (A) to the spherical tie-rod (4). Undo the indicated screws fastening the stabiliser bar (A) to the chassis, retrieving the retainer bracket (5). Undo the indicated screws fastening the stabiliser bar (A) to the chassis, retrieving the retainer bracket (5).
Page 964 Stabiliser bars - Tie-rods Page 7 of 10 Remove the stabiliser bar (A) from the chassis, easing out from one side. Refitting the front stabiliser bar Tightening torque Class Fastening front stabiliser bar to chassis Screw 30 Nm Fastening rear stabiliser bar to tie-rod 50 Nm Apply 1 ml of DuPont Lubricants Krytox®...
Page 965 Stabiliser bars - Tie-rods Page 8 of 10 Fit the stabiliser bar (A) in the relative seat on the chassis, with the notch (6) nearest to the outer edge on the bushing facing forward. Fit the retainer bracket (5) on the bushing and tighten the indicated screws.
Page 966 Stabiliser bars - Tie-rods Page 9 of 10 Fit and tighten the nut (1) fastening the stabiliser bar (A) to the spherical tie-rod (2). Tightening torque Class 50 Nm Refit the wheels ( D2.01). Replacing front spherical tie-rods Tightening torque Class Spherical tie-rod - lower arm Spherical tie-rod...
Page 967 Stabiliser bars - Tie-rods Page 10 of 10 Refit the wheels ( D2.01).
Page 968 This vehicle is equipped with the latest generation MagneRide™ magnetorheologically controlled suspension, a system that continuously and automatically controls suspension damping developed by Delphi and honed by Ferrari. By processing data received from the vehicle dynamics sensors measuring the movements of the bodyshell, the ECU determines the road surface conditions and instantaneously adapts the response of the suspension accordingly, by varying the control current for each shock absorber.
Page 969 Suspension damping control system Page 2 of 5 The magnetorheological (MR) fluid is an oil containing a suspension of spherical ferromagnetic particles measuring a few microns in diameter. Using an electric current to apply a magnetic field to the oil, the viscosity of the oil may be varied. By varying the magnetic field applied to the MR fluid flowing in a duct, its pressure and flow rate characteristics may be adjusted in real time without the use of any external mechanical moving parts or actuators.
Page 970 Suspension damping control system Page 3 of 5 The system consists of: 4 NRRPS (Non-Contacting Ratiometer Rotational Position Sensor) sensors installed on the suspension of each wheel, in which the fixed part of the potentiometer is mounted on the chassis (sprung mass) while the rotating part of the potentiometer moves together with the suspension.
Page 971 Suspension damping control system Page 4 of 5 Disconnect the battery ( F2.01). Remove the wheels ( D2.01). Remove the relative front wheel only. Disconnect the connector (1). Detach the tie-rod (2) from the upper arm. Undo the two indicated screws fastening the front motion sensor mounting bracket (A).
Page 972 Suspension damping control system Page 5 of 5 Disconnect the connector (1). Detach the tie-rod (2) from the lower arm. Undo the two indicated screws fastening the rear NRRPS motion sensor mounting bracket (A). Remove the rear NRRPS motion sensor (A), complete with relative mounting bracket, and replace.
Page 973 Vehicle set-up Page 1 of 4 Print Exit D4.07 Vehicle set-up Checks and preparation of vehicle Check the following before inspecting the set-up: Wheel fastening; Tyre pressure; Clearance between pinion and rack in steering system; Clearance between ball studs and steering tie-rods; State of the shock absorbers;...
Page 974 Vehicle set-up Page 2 of 4 Total On wheel Front -2 ± 0.5 mm -1 ± 0.25 mm Rear 3 ± 0.5 mm 1.5 ± 0.25 mm Height check With the vehicle arranged as specified above, the correct height of the vehicle measured between the ground and the front section of the chassis, measured in relation to the point (A) (external surface of the hole), must correspond to the specified set-up values.
Page 975 Vehicle set-up Page 3 of 4 Check that the lower suspension arms are in the correct position. After checking, if the camber angle is not within the prescribed values, loosen the nuts (1) and fit new shims (2) to obtain a camber angle between the prescribed values, proceeding as described in chapter D4.02. - Toe-in - After checking, if the toe-in is not within the prescribed values, proceed as follows: Make sure that the steering box is in central position and that the steering wheel is perfectly horizontal.
Page 976 Vehicle set-up Page 4 of 4 Check that the lower suspension arms are in the correct position. After checking, if the camber angle is not within the prescribed values, loosen the nuts (5) and fit new shims (6) to obtain a camber angle between the prescribed values, proceeding as described in chapter D4.02. - Toe-in - After checking, if the toe-in is not within the prescribed values, proceed as follows: Loosen the nuts (7) and turn the tie-rods (8), adjusting both tie-rods by the same amount, to obtain a toe-in...
Page 977 “Front Lift” ramp clearing front suspension lift (optional) Page 1 of 10 Print Exit D4.08 “Front Lift” ramp clearing front suspension lift (optional) System layout A - Tank B - Electric pump C - Union block Operating the "Front Lift" system CAUTION The system is not designed to remain active with the engine switched off while the vehicle is parked.
Page 978 “Front Lift” ramp clearing front suspension lift (optional) Page 2 of 10 The “Front Lift” system uses the front shock absorbers to raise the front of the vehicle by approximately 40 mm, to allow access to garages or steep ramps without damaging the vehicle. The “Front Lift”...
Page 979 “Front Lift” ramp clearing front suspension lift (optional) Page 3 of 10 If the ignition switch is turned to 0 while the system is active, the TFT display displays the vehicle symbol with a white arrow pointing upward with the specific message "Front Lift ON", together with the message "Set Front Lift to OFF".
Page 980 “Front Lift” ramp clearing front suspension lift (optional) Page 4 of 10 If the system is inhibited, the TFT display shows the vehicle symbol with a red arrow pointing upward together with the specific message "Front Lift inhibited". Removing the "Front Lift" system electric pump The electric pump is located in front of the rear right hand wheel bay.
Page 981 “Front Lift” ramp clearing front suspension lift (optional) Page 5 of 10 Disconnect the union (3). Undo the union (1) on the pipe (2). Place a container under the pipe (2). Pour the fluid drained from the system into a container and seal it.
Page 982 “Front Lift” ramp clearing front suspension lift (optional) Page 6 of 10 Check that state of the adhesive pad applied to the electric pump (A) and replace if necessary. Fit the electric pump (A) in the relative seat. Hand tighten the screws indicated. Tightening torque Class Screw...
Page 983 “Front Lift” ramp clearing front suspension lift (optional) Page 7 of 10 Reconnect the battery ( F2.01). Fill and bleed the "Front Lift" system ( D4.08). Refit the door sill trim panel ( E3.11). Refit the rear flat undertray section ( E3.12).
Page 984 “Front Lift” ramp clearing front suspension lift (optional) Page 8 of 10 Fit the reservoir (A). Hand tighten the screws indicated. Tightening torque Class Screw 4 Nm Connect pipe (1). Tighten a new clamp as indicated. Fill and bleed the "Front Lift" system ( D4.08).
Page 985 “Front Lift” ramp clearing front suspension lift (optional) Page 9 of 10 Turn the ignition switch on. Wait at least 10 seconds. Connect the DEIS diagnostic tester to the diagnostic socket ( F2.10). Start the "NSV bleeding" cycle, using the DEIS diagnostic tester and following the relative instructions. Wait at least 5 seconds.
Page 986 “Front Lift” ramp clearing front suspension lift (optional) Page 10 of 10 Check that the fluid level in the reservoir (A) is near the MAX limit. If the level is near the MIN limit, top the system up with fluid as follows. Undo the cap (1).
Page 987 Steering system layout Page 1 of 1 Print Exit D5.01 Steering system layout Steering system layout A - Power steering fluid tank B - Power steering fluid pump C - Steering box D - Power steering fluid radiator E - Steering column F - Steering wheel...
Page 988 Power steering tank Page 1 of 3 Print Exit D5.02 Power steering tank Removing the power steering tank CAUTION The oil contained in the hydraulic steering system is harmful to the eyes and skin and may also damage the vehicle bodywork. Pour the oil drained from the system into a container and seal it.
Page 989 Power steering tank Page 2 of 3 Disconnect the breather pipe from the cap (1). Undo the fastener screws indicated and lift the power steering reservoir (A). Disconnect the two pipes (2) from the power steering tank (A), loosening the relative clamps. Remove the power steering tank (A).
Page 990 Power steering tank Page 3 of 3 Connect the two pipes (2) to the power steering tank (A) by tightening the relative clamps. Tightening torque Class Screw collar 4 Nm Screw collar 4 Nm Fit the power steering tank (A) onto its mounting bracket.
Page 991 Power steering pump Page 1 of 7 Print Exit D5.03 Power steering pump Removing the power steering pump The majority of cases of NOISY power steering pump operation are caused by contaminated fluid in the system; therefore, attempt to rectify the failure before replacing the power steering pump, replacing the power steering fluid tank ALWAYS.
Page 992 Power steering pump Page 2 of 7 Undo the screw indicated fastening the heat shield to the power steering pump (2). Remove the heat shield on the power steering pump (2), undoing the screw indicated. Undo the rear screw indicated fastening the power steering pump (A) to the engine.
Page 993 Power steering pump Page 3 of 7 Remove the cover (3) by undoing the screws indicated. Undo the two front screws indicated fastening the power steering pump (A) to the engine. Retrieve the pipe guard. Holding the power steering pump (A), undo the union (4) on the rigid pipe and remove the clamp (5) on the hose.
Page 994 Power steering pump Page 4 of 7 Tightening torque Class Fastening rigid pipe to power steering pump Union 37 Nm Fastening A.C. compressor heat shield Screw 9 Nm Fastening power steering pump to engine Screw 25 Nm Fastening cover to power steering pump Screw 10 Nm The majority of cases of NOISY power steering pump operation are caused by contaminated fluid in the...
Page 995 Power steering pump Page 5 of 7 Hand tighten the indicated rear screw (13) fastening the power steering pump (A) to the engine. Fit the cover (3) onto the power steering pump and fasten by hand tightening the screws (8). Fit the heat shield on the power steering pump (2) and fasten by tightening the screw indicated.
Page 996 Power steering pump Page 6 of 7 Tighten the screw indicated fastening the heat shield to the power steering pump (2). Fit and fasten the heat shield on the compressor (1), tightening the screw indicated. Tightening torque Class Screw 9 Nm Refit the compressor ( F5.03).
Page 997 Power steering pump Page 7 of 7 Tighten the indicated rear screw (13) fastening the power steering pump (A) to the engine. Tightening torque Class Screw 25 Nm Refit the compressor ( F5.03). Tighten the screws fastening the AC compressor. Tighten the screws indicated fastening the cover (3).
Page 998 Steering box Page 1 of 8 Print Exit D5.04 Steering box Removing the steering box Disconnect the battery ( F2.01). Remove the luggage compartment tub ( E4.07). Remove the front flat undertray section ( E3.12). Remove the wheels ( D2.01). Remove the front wheels.
Page 999 Steering box Page 2 of 8 Undo the nut (2) fastening the right hand tie-rod (B) to the right hand hub carrier (C). Disconnect the right hand tie-rod (B) from the right hand hub carrier (C). Undo the screw (3) fastening the universal joint (D) linking the steering column (E) with the steering box.
Page 1000 Steering box Page 3 of 8 On the right-hand side, undo the two screws indicated fastening the steering box (A) to the chassis. Retrieve the mounting (4) and the relative shim (5). Remove the clamp (6) retaining the steering box cables (A).
Page 1001 Steering box Page 4 of 8 Rotating clockwise by just enough to allow its removal from the front left hand wheel bay, remove the steering box (A) from the relative seat. Refitting the steering box Tightening torque Class Fastening retainer bracket on recirculation pump Screw 9 Nm Fastening steering box to chassis...
Page 1002 Steering box Page 5 of 8 Fit the water recirculation pump (F), complete with mounting bracket, in the relative seat, after installing the steering box (A) correctly. Tighten the two screws indicated fastening the recirculation pump mounting bracket (F). Tightening torque Class Screw 9 Nm...
Page 1003 Steering box Page 6 of 8 On the left hand side, tighten the indicated screws fastening the steering box (A) to the chassis. Pre-tighten and definitively tighten the steering box fastener screws in a cross pattern. Tightening torque Class Nut (pretightening) 25 Nm Screw 60 Nm...
Page 1004 Steering box Page 7 of 8 Connect the right hand tie-rod (B) to the right hand hub carrier (C). Pre-tighten, loosen and then definitively tighten the nut (2) fastening the right hand tie-rod (B) to the right hand hub carrier (C). Tightening torque Class 40 Nm...
Page 1005 Steering box Page 8 of 8 Refit the luggage compartment tub ( E4.07). Reconnect the battery ( F2.01). Fill the power steering system ( D5.08).

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